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Summary of Content
Factory Workshop Manual
Make
Ford
Model
Expedition 4wd
Engine and year
V8-5.4L SOHC VIN 5 (2005)
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 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010
P0010
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 9
P0011
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 10
P0012
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020
P0020
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 15
P0021
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 16
P0022
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044,
( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040
P0040
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044,
( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > Page 21
P0041
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054,
( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis
P005x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0060 - P0064,
( P0061 P0062 P0063 0060 0061 0062 0063 0064 ) > System Information > System Diagnosis > P0060
P0060
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0060 - P0064,
( P0061 P0062 P0063 0060 0061 0062 0063 0064 ) > System Information > System Diagnosis > P0060 > Page 29
P0061
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0065 - P0069,
( P0066 P0067 P0068 0065 0066 0067 0068 0069 ) > System Information > System Diagnosis
P0068
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0102 (Part 1)
P0102 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 38
P0103
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 39
P0104
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0106
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 44
P0105 - P0109: Testing and Inspection P0107
P0107 (Part 1)
P0107 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 45
P0108
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 46
P0109
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0112
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 51
P0113
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 52
P0114
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116
P0115 - P0119: Testing and Inspection P0116
P0116 (Part 1)
P0116 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 57
P0117
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 58
P0115 - P0119: Testing and Inspection P0118
P0118 (Part 1)
P0118 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 59
P0119
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0121 (Part 1)
P0121 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 64
P0122
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 65
P0120 - P0124: Testing and Inspection P0123
P0123 (Part 1)
P0123 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 70
P0127
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 71
P0128
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0131
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 76
P0132
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 77
P0133
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 82
P0136
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 83
P0138
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144,
( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > P0141
P0141
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144,
( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > P0141 > Page 88
P0144
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149,
( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > P0147
P0147
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149,
( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > P0147 > Page 93
P0148
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0151
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 98
P0152
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 99
P0153
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 104
P0156
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 105
P0158
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0161
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0165 - P0169,
( P0166 P0167 P0168 0165 0166 0167 0168 0169 ) > System Information > System Diagnosis
P0167
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0171
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 116
P0172
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 117
P0174
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0180 (Part 1)
P0180 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 125
P0181
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 126
P0182
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 127
P0183
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 132
P0190 - P0194: Testing and Inspection P0191
P0191 (Part 1)
P0191 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 133
P0192
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 134
P0193
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196
P0196
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 139
P0197
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 140
P0198
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P020x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > P0217
P0217
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > P0217 > Page 152
P0215 - P0219: Testing and Inspection P0218
P0218
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > P0217 > Page 153
P0215 - P0219: Testing and Inspection P0219
P0219
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221
P0221
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 158
P0222
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 159
P0223
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 164
P0231
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 165
P0230 - P0234: Testing and Inspection P0232
P0232 (Part 1)
P0232 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 166
P0234
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244,
( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis
P0243
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264,
( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis > P0261
P0261
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264,
( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis > P0261 > Page 174
P0262
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264,
( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis > P0261 > Page 175
P0264
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269,
( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis > P0265
P0265
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269,
( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis > P0265 > Page 180
P0267
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269,
( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis > P0265 > Page 181
P0268
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274,
( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270
P0270
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274,
( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 > Page 186
P0271
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274,
( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 > Page 187
P0273
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274,
( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 > Page 188
P0274
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279,
( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis > P0276
P0276
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279,
( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis > P0276 > Page 193
P0277
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279,
( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis > P0276 > Page 194
P0279
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284,
( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis > P0280
P0280
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284,
( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis > P0280 > Page 199
P0282
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284,
( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis > P0280 > Page 200
P0283
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299,
( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297
P0297
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299,
( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 > Page 205
P0295 - P0299: Testing and Inspection P0298
P0298 (Part 1)
P0298 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P030x
P030x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P030x > Page 211
P0300
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0310 (Part 1)
P0310 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319,
( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315
P0315
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319,
( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 219
P0316
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 227
P0326
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 232
P0331
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0340 (Part 1)
P0340 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349,
( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis
P0345
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 243
P0351
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 244
P0352
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 245
P0353
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 246
P0354
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 251
P0356
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 252
P0357
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 253
P0355 - P0359: Testing and Inspection P0358
P0358 (Part 1)
P0358 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 254
P0359
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400
P0400
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 263
P0401
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 264
P0402
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 265
P0403
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409,
( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405
P0405
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409,
( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 270
P0406
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0411
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 275
P0410 - P0414: Testing and Inspection P0412
P0412 (Part 1)
P0412 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0442
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 286
P0443
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0445 - P0449,
( P0446 P0447 P0448 0445 0446 0447 0448 0449 ) > System Information > System Diagnosis
P0445 - P0449: Testing and Inspection
P0446 (Part 1)
P0446 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0451
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 294
P0452
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 295
P0450 - P0454: Testing and Inspection P0453
P0453 (Part 1)
P0453 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 296
P0454
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 301
P0455 - P0459: Testing and Inspection P0456
P0456 (Part 1)
P0456 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 302
P0457
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 307
P0461
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 308
P0462
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 309
P0463
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480
P0480
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 314
P0480 - P0484: Testing and Inspection P0481
P0481 (Part 1)
P0481 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 315
P0482
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0500 (Part 1)
P0500 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 321
P0503
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505
P0505
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 326
P0505 - P0509: Testing and Inspection P0506
P0506 (Part 1)
P0506 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 327
P0507
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514,
( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis
P0510 - P0514: Testing and Inspection
P0511 (Part 1)
P0511 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534,
( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > P0532
P0532
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534,
( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > P0532 > Page 335
P0533
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534,
( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > P0532 > Page 336
P0534
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539,
( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537
P0535 - P0539: Testing and Inspection P0537
P0537 (Part 1)
P0537 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539,
( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 341
P0538
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P0552
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 346
P0553
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0560 - P0564,
( P0561 P0562 P0563 0560 0561 0562 0563 0564 ) > System Information > System Diagnosis > P0562
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0560 - P0564,
( P0561 P0562 P0563 0560 0561 0562 0563 0564 ) > System Information > System Diagnosis > P0562 > Page 351
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0575 - P0579,
( P0576 P0577 P0578 0575 0576 0577 0578 0579 ) > System Information > System Diagnosis > Engine Related Testing
P0575 - P0579: Testing and Inspection Engine Related Testing
P0579 (Part 1)
P0579 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0575 - P0579,
( P0576 P0577 P0578 0575 0576 0577 0578 0579 ) > System Information > System Diagnosis > Engine Related Testing >
Page 356
P0575 - P0579: Testing and Inspection Cruise Control Related Testing
For diagnosis of code P0579, refer to chart:
P0500-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 Cruise Control system, follow this link: See: Cruise Control/Testing
and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0580 - P0584,
( P0581 P0582 P0583 0580 0581 0582 0583 0584 ) > System Information > System Diagnosis > Engine Related Diagnosis
P0581
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0580 - P0584,
( P0581 P0582 P0583 0580 0581 0582 0583 0584 ) > System Information > System Diagnosis > Engine Related Diagnosis
> Page 361
P0580 - P0584: Testing and Inspection Cruise Control Related Diagnosis
For diagnosis of code P0581, refer to chart:
P0500-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 Cruise Control system, follow this link: See: Cruise Control/Testing
and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600
P0600
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600 > Page 367
P0602
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600 > Page 368
P0603
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609,
( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605
P0605
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609,
( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 > Page 373
P0606
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0610 - P0614,
( P0611 P0612 P0613 0610 0611 0612 0613 0614 ) > System Information > System Diagnosis > P0611
P0611
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0610 - P0614,
( P0611 P0612 P0613 0610 0611 0612 0613 0614 ) > System Information > System Diagnosis > P0611 > Page 378
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P061F - P061J,
( P061G P061H P061I 061F 061G 061H 061I 061J ) > System Information > System Diagnosis
P061F
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624,
( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620
P0620
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624,
( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 386
P0622
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0630 - P0634,
( P0631 P0632 P0633 0630 0631 0632 0633 0634 ) > System Information > System Diagnosis
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0640 - P0644,
( P0641 P0642 P0643 0640 0641 0642 0643 0644 ) > System Information > System Diagnosis
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649,
( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis
P0645 - P0649: Testing and Inspection
P0645 (Part 1)
P0645 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0655 - P0659,
( P0656 P0657 P0658 0655 0656 0657 0658 0659 ) > System Information > System Diagnosis > P0657
P0657
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0655 - P0659,
( P0656 P0657 P0658 0655 0656 0657 0658 0659 ) > System Information > System Diagnosis > P0657 > Page 400
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0655 - P0659,
( P0656 P0657 P0658 0655 0656 0657 0658 0659 ) > System Information > System Diagnosis > P0657 > Page 401
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664,
( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis > P0660
P0660
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664,
( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis > P0660 > Page 406
P0663
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0665 - P0669,
( P0666 P0667 P0668 0665 0666 0667 0668 0669 ) > System Information > System Diagnosis
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P0701
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P0701 > Page 415
P0700 - P0704: Testing and Inspection P0703
P0703
Cruise Control Related Diagnosis
For diagnosis of code P0703, refer to chart:
P0500-P0703
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Cruise Control system, follow this link: See: Cruise Control/Testing
and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P0701 > Page 416
P0704
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 421
P0707
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 422
P0705 - P0709: Testing and Inspection P0708
P0708 (Part 1)
P0708 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P071x
P071x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P071x > Page 427
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P071x > Page 428
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P071x > Page 429
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P071x > Page 430
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 435
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 436
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720
P0720
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 > Page 441
P0721
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 > Page 442
P0722
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 > Page 443
P0723
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P073x
P073x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P073x > Page 451
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P073x > Page 452
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P073x > Page 453
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P073x > Page 454
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739,
( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > P0735
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739,
( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > P0735 > Page 459
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P074x
P074x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P074x > Page 464
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P074x > Page 465
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P075x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764,
( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis
P076x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0770 - P0774,
( P0771 P0772 P0773 0770 0771 0772 0773 0774 ) > System Information > System Diagnosis > P077x
P077x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0770 - P0774,
( P0771 P0772 P0773 0770 0771 0772 0773 0774 ) > System Information > System Diagnosis > P077x > Page 476
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P078x
P078x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P078x > Page 481
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P078x > Page 482
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P078x > Page 483
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis
P079x
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0815 - P0819,
( P0816 P0817 P0818 0815 0816 0817 0818 0819 ) > System Information > System Diagnosis
P0815
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0830 - P0834,
( P0831 P0832 P0833 0830 0831 0832 0833 0834 ) > System Information > System Diagnosis > P0830
P0830
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0830 - P0834,
( P0831 P0832 P0833 0830 0831 0832 0833 0834 ) > System Information > System Diagnosis > P0830 > Page 495
P0833
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0840 - P0844,
( P0841 P0842 P0843 0840 0841 0842 0843 0844 ) > System Information > System Diagnosis
P0840
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0900 - P0904,
( P0901 P0902 P0903 0900 0901 0902 0903 0904 ) > System Information > System Diagnosis
P09xx
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 508
P1001
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 514
P1101
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112
P1112
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 519
P1114
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115
P1115
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 524
P1116
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 525
P1117
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 530
P1120 - P1124: Testing and Inspection P1121
P1121 (Part 1)
P1121 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 531
P1124
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 536
P1127
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 537
P1128
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 538
P1129
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1130 (Part 1)
P1130 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 543
P1131
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 544
P1132
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1137
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 549
P1138
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 554
P1151
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 555
P1152
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P1156
P1156
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P1156 > Page 560
P1157
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 > P1156 > Page 561
P1158
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis
P1184
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229,
( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis
P1229
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1233
P1233
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1233 > Page 573
P1234
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 578
P1236
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 579
P1235 - P1239: Testing and Inspection P1237
P1237 (Part 1)
P1237 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 580
P1238
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1244
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1245 (Part 1)
P1245 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 588
P1246
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260
P1260
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 593
P1261
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 594
P1262
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 595
P1263
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 596
P1264
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269,
( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265
P1265
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269,
( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 > Page 601
P1266
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269,
( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 > Page 602
P1267
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269,
( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 > Page 603
P1268
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270
P1270
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 608
P1271
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 609
P1272
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 610
P1273
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 611
P1274
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279,
( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275
P1275
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279,
( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 > Page 616
P1276
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279,
( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 > Page 617
P1277
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279,
( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 > Page 618
P1278
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1285 (Part 1)
P1285 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 623
P1288
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 624
P1289
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1299
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1309
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1335 - P1339,
( P1336 P1337 P1338 1335 1336 1337 1338 1339 ) > System Information > System Diagnosis
P1336
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 642
P1381
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 643
P1383
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1385
P1385
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1385 > Page 648
P1386
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1385 > Page 649
P1388
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 655
P1401
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 660
P1406
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 661
P1408
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 662
P1409
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439,
( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436
P1436
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439,
( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 667
P1437
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1443
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 675
P1451
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 680
P1461
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 681
P1462
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 682
P1463
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 683
P1464
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1469 (Part 1)
P1469 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1474
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477
P1477
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 694
P1479
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1485 - P1489,
( P1486 P1487 P1488 1485 1486 1487 1488 1489 ) > System Information > System Diagnosis
P1489
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1500 (Part 1)
P1500 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 703
P1501
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 704
P1500 - P1504: Testing and Inspection P1502
P1502 (Part 1)
P1502 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 705
P1504
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1506
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 710
P1507
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1512
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 715
P1513
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1516
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 720
P1517
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 721
P1518
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 722
P1519
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1537
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 730
P1538
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1549
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565
P1565 - P1569: Testing and Inspection P1565
P1565 (Part 1)
P1565 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 741
P1566
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 742
P1567
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 743
P1568
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574,
( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Engine Related Diagnosis
P1572
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574,
( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Engine Related Diagnosis
> Page 748
P1570 - P1574: Testing and Inspection Cruise Control Related Diagnosis
For diagnosis of code P1572, refer to chart:
P0500-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 Cruise Control system, follow this link: See: Cruise Control/Testing
and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1580 - P1584,
( P1581 P1582 P1583 1580 1581 1582 1583 1584 ) > System Information > System Diagnosis
P1582
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1633
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 760
P1636
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 761
P1635 - P1639: Testing and Inspection P1639
P1639 (Part 1)
P1639 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644,
( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > P1640
P1640
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644,
( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > P1640 > Page 766
P1641
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 771
P1651
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1670 - P1674,
( P1671 P1672 P1673 1670 1671 1672 1673 1674 ) > System Information > System Diagnosis
P1674
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P17xx
P17xx
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P17xx > Page 780
P1700 - P1704: Testing and Inspection P1703
P1703
Cruise Control Related Diagnosis
For diagnosis of code P1703, refer to chart:
P0500-P1703
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 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P17xx > Page 781
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Cruise Control system, follow this link: See: Cruise Control/Testing
and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 786
P1709
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P1729
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 794
P1780 - P1784: Testing and Inspection P1781
P1781 (Part 1)
P1781 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
P18xx
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 809
P1820 - P1824: Testing and Inspection P1822
For diagnosis of code P1822, 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 Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 810
P1820 - P1824: Testing and Inspection P1824
For diagnosis of code P1824, 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 Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 815
P1825 - P1829: Testing and Inspection P1827
For diagnosis of code P1827, 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 Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 816
P1825 - P1829: Testing and Inspection P1828
For diagnosis of code P1828, 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 Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1845 - P1849,
( P1846 P1847 P1848 1845 1846 1847 1848 1849 ) > System Information > System Diagnosis
P1845 - P1849: Testing and Inspection
For diagnosis of code P1849, refer to chart:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854,
( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis
P1850 - P1854: Testing and Inspection
For diagnosis of code P1853, refer to chart:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1855 - P1859,
( P1856 P1857 P1858 1855 1856 1857 1858 1859 ) > System Information > System Diagnosis
P1855 - P1859: Testing and Inspection
For diagnosis of code P1857, refer to chart:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1860 - P1864,
( P1861 P1862 P1863 1860 1861 1862 1863 1864 ) > System Information > System Diagnosis
P1860 - P1864: Testing and Inspection
For diagnosis of code P1861, refer to chart:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869,
( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis
P1865 - P1869: Testing and Inspection
For diagnosis of code P1867, refer to chart:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894,
( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis
P1890 - P1894: Testing and Inspection
For diagnosis of code P1891, refer to chart:
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > P1900
P1900
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > P1900 > Page 843
P1900 - P1904: Testing and Inspection P1901
P1901 (Part 1)
P1901 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1910 - P1914,
( P1911 P1912 P1913 1910 1911 1912 1913 1914 ) > System Information > System Diagnosis
P1910
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2000 - P2004,
( P2001 P2002 P2003 2000 2001 2002 2003 2004 ) > System Information > System Diagnosis
P2004
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005
P2005
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 855
P2006
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 856
P2007
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 857
P2008
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2010 - P2014,
( P2011 P2012 P2013 2010 2011 2012 2013 2014 ) > System Information > System Diagnosis
P2014
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019,
( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis > P2015
P2015
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019,
( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis > P2015 > Page 865
P2015 - P2019: Testing and Inspection P2019
P2019 (Part 1)
P2019 (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2020 - P2024,
( P2021 P2022 P2023 2020 2021 2022 2023 2024 ) > System Information > System Diagnosis
P2020
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069,
( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065
P2065
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069,
( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 > Page 873
P2066
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069,
( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 > Page 874
P2067
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069,
( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 > Page 875
P2068
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070
P2070
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 880
P2071
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 881
P2072
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2100 - P2104,
( P2101 P2102 P2103 2100 2101 2102 2103 2104 ) > System Information > System Diagnosis > P2100
P2100
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2100 - P2104,
( P2101 P2102 P2103 2100 2101 2102 2103 2104 ) > System Information > System Diagnosis > P2100 > Page 887
P2101
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2100 - P2104,
( P2101 P2102 P2103 2100 2101 2102 2103 2104 ) > System Information > System Diagnosis > P2100 > Page 888
P2104
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2105 - P2109,
( P2106 P2107 P2108 2105 2106 2107 2108 2109 ) > System Information > System Diagnosis > P2105
P2105
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2105 - P2109,
( P2106 P2107 P2108 2105 2106 2107 2108 2109 ) > System Information > System Diagnosis > P2105 > Page 893
P2106
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2105 - P2109,
( P2106 P2107 P2108 2105 2106 2107 2108 2109 ) > System Information > System Diagnosis > P2105 > Page 894
P2107
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2110 - P2114,
( P2111 P2112 P2113 2110 2111 2112 2113 2114 ) > System Information > System Diagnosis > P2110
P2110
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2110 - P2114,
( P2111 P2112 P2113 2110 2111 2112 2113 2114 ) > System Information > System Diagnosis > P2110 > Page 899
P2111
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2110 - P2114,
( P2111 P2112 P2113 2110 2111 2112 2113 2114 ) > System Information > System Diagnosis > P2110 > Page 900
P2112
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2120 - P2124,
( P2121 P2122 P2123 2120 2121 2122 2123 2124 ) > System Information > System Diagnosis > P2121
P2121
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2120 - P2124,
( P2121 P2122 P2123 2120 2121 2122 2123 2124 ) > System Information > System Diagnosis > P2121 > Page 905
P2122
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2120 - P2124,
( P2121 P2122 P2123 2120 2121 2122 2123 2124 ) > System Information > System Diagnosis > P2121 > Page 906
P2123
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2125 - P2129,
( P2126 P2127 P2128 2125 2126 2127 2128 2129 ) > System Information > System Diagnosis > P2126
P2126
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2125 - P2129,
( P2126 P2127 P2128 2125 2126 2127 2128 2129 ) > System Information > System Diagnosis > P2126 > Page 911
P2127
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2125 - P2129,
( P2126 P2127 P2128 2125 2126 2127 2128 2129 ) > System Information > System Diagnosis > P2126 > Page 912
P2128
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2130 - P2134,
( P2131 P2132 P2133 2130 2131 2132 2133 2134 ) > System Information > System Diagnosis > P2131
P2131
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2130 - P2134,
( P2131 P2132 P2133 2130 2131 2132 2133 2134 ) > System Information > System Diagnosis > P2131 > Page 917
P2132
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2130 - P2134,
( P2131 P2132 P2133 2130 2131 2132 2133 2134 ) > System Information > System Diagnosis > P2131 > Page 918
P2133
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2135 - P2139,
( P2136 P2137 P2138 2135 2136 2137 2138 2139 ) > System Information > System Diagnosis
P2135
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195
P2195
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 926
P2196
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 927
P2197
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 928
P2198
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259,
( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257
P2257
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259,
( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257 > Page 934
P2258
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270
P2270
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 939
P2271
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 940
P2272
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 941
P2273
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 942
P2274
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2275 - P2279,
( P2276 P2277 P2278 2275 2276 2277 2278 2279 ) > System Information > System Diagnosis > P2275
P2275
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2275 - P2279,
( P2276 P2277 P2278 2275 2276 2277 2278 2279 ) > System Information > System Diagnosis > P2275 > Page 947
P2278
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 954
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 955
Accessory Delay Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 956
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Application and ID
Keyless Entry Module: Application and ID
RKE TRANSMITTER/RKE KEYPAD
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit
Navigation Module: Diagrams Audio/Navigation Control Unit
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 965
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 966
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 967
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 968
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 969
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 970
Navigation Module: Diagrams Navigation Module
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams > Page 971
Navigation Module: Service and Repair
NAVIGATION SYSTEM MODULE
Removal and Installation
1. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
NOTE: Prior to removal of the navigation system module, it is necessary to remove the digital
versatile disc (DVD) from the navigation system module and store it in the customer case.
Disconnect the battery.
2. Remove the lower LH and RH panels from the front floor console.
3. Remove the navigation system module.
- Remove the electrical connectors.
- Remove the screws.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 > Oct > 06 >
Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC
C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 > Oct > 06 >
Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 980
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-20-5 >
Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker
Inop./DTC C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-20-5 >
Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 986
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking
Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking
Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 992
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 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking
Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 993
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 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking
Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 999
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 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking
Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1000
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 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > Page 1001
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > Page 1002
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Technical Service Bulletins > Page 1003
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Removal and Installation
All vehicles 1. Remove the LH quarter trim panel.
Navigator
2. Remove the parking aid module.
- Disconnect the electrical connector.
- Remove the screw.
Expedition
3. Remove the parking aid module.
- Disconnect the electrical connectors.
- Remove the screws.
All vehicles 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Application and ID
Keyless Entry Module: Application and ID
RKE TRANSMITTER/RKE KEYPAD
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 1011
Memory Positioning Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 1012
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Application and ID
Power Door Lock Control Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Application and ID
Power Seat Control Module: Application and ID
THIRD ROW POWER-FOLD SEAT
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Diagrams > Third Row Folding Seat Relay, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 1024
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 1027
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 1028
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 1029
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 1033
Power Trunk / Liftgate Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 1034
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 1035
Power Trunk / Liftgate Control Module: Service and Repair
POWER LIFTGATE MODULE
Removal and Installation
NOTE: Prior to removal of the power liftgate module, it is necessary to upload module configuration
information to a diagnostic tool. This information needs to be downloaded into the new power
liftgate module once installed.
1. Remove the rear quarter trim panel.
2. Remove the power liftgate module.
1 Disconnect the electrical connectors.
2 Remove the bolts.
3. NOTE: Once the new power liftgate module is installed, it is necessary to download the module
configuration information from the diagnostic
tool into the new power liftgate module.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 07-16-8 > Aug
> 07 > A/C - Front Seat Heaters Inoperative
Seat Heater Control Module: Customer Interest A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 07-16-8 > Aug
> 07 > A/C - Front Seat Heaters Inoperative > Page 1044
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1049
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1050
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1051
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1052
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1053
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1054
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1055
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1056
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1057
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative
Seat Heater Control Module: All Technical Service Bulletins A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
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07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative > Page 1065
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
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06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Component Information > Technical Service Bulletins > Page 1081
View 151-27 (Passenger Seat)
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Component Information > Technical Service Bulletins > Page 1082
Seat Heater Control Module: Diagrams
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Component Information > Technical Service Bulletins > Page 1083
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Component Information > Technical Service Bulletins > Page 1084
Seat Heater Control Module: Service and Repair
CLIMATE CONTROLLED SEAT MODULE
Removal and Installation
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Position the front passenger seat all the way back and up. 2. Depower the SRS.
3. Pull out and remove the lower front seat track shield.
4. NOTE: The inset shows the dual climate control seat module (CCSM) retaining bracket.
Remove the dual CCSM. 1
Pull the back of the dual CCSM away from the seat and slide it off the mounting bracket.
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2 Disconnect the electrical connectors.
3 Remove the dual CCSM.
5. To install, reverse the removal procedure. 6. Repower the SRS.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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- Climate Controlled Seats DTC B272C or B272D > Page 1094
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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- Climate Controlled Seats DTC B272C or B272D > Page 1095
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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- Climate Controlled Seats DTC B272C or B272D > Page 1096
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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- Climate Controlled Seats DTC B272C or B272D > Page 1097
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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- Climate Controlled Seats DTC B272C or B272D > Page 1098
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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- Climate Controlled Seats DTC B272C or B272D > Page 1099
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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- Climate Controlled Seats DTC B272C or B272D > Page 1100
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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- Climate Controlled Seats DTC B272C or B272D > Page 1101
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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- Climate Controlled Seats DTC B272C or B272D > Page 1102
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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- Climate Controlled Seats DTC B272C or B272D > Page 1103
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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- Climate Controlled Seats DTC B272C or B272D > Page 1104
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 >
Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 >
Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1110
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 >
Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1111
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1112
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1116
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Component Information > Locations
View 151-23 (Roof)
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Component Information > Locations
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Trailer Towing Relay: Testing and Inspection
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Control Module > Component Information > Locations
View 151-2 (Engine Compartment)
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Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
NOTE: When installing a new module, it must be calibrated and configured (either by
download/upload or uploading the as-built data method).
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery.
2. Disconnect the ABS module electrical connector.
3. Remove the 3 bolts and the ABS module. 4. To install, reverse the removal procedure
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Blower Motor Relay: Locations Front Blower Motor Relay
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View 151-1 (Engine Compartment)
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Blower Motor Relay: Locations Rear Blower Motor Relay
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View 151-21 (Right Rear)
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Blower Motor Relay: Testing and Inspection Front Blower Motor Relay
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Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay
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Compressor Clutch Relay: Locations
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View 151-1 (Engine Compartment)
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Compressor Clutch Relay: Description and Operation
AIR CONDITIONING CLUTCH RELAY (A/CCR)
NOTE: The PCM PIDs WAC and WACF are used to monitor the A/CCR output.
The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally
open. There is no direct electrical connection between the A/C switch or EATC module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the communications network). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as 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 A/CCR output, closing the relay contacts and sending
voltage to the A/C clutch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1159
Compressor Clutch Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1160
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 1164
Control Module HVAC: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 1165
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
05-22-10 > Nov > 05 > Instruments - Outside Temperature Display Inaccurate
Instrument Panel Control Module: Customer Interest Instruments - Outside Temperature Display
Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
05-9-12 > May > 05 > Instruments - 'Check Park Assist' Displayed
Instrument Panel Control Module: Customer Interest Instruments - 'Check Park Assist' Displayed
TSB 05-9-12
05/16/05
"CHECK PARK ASSIST" DISPLAYED IN MESSAGE CENTER - VEHICLES BUILT PRIOR TO
4/1/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built prior to 4/1/2005 and equipped with a
message center, may display a "Check Park Assist" message with no diagnostic trouble codes
(DTCs) present in the message center.
ACTION Reprogram the cluster to the latest calibration using WDS release B37.2 or higher.
Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050912A 2005 Expedition/Navigator 0.3 Hr.
Check For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With
12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14026 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 05-22-10 > Nov > 05 > Instruments - Outside Temperature Display Inaccurate
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Outside
Temperature Display Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 05-9-12 > May > 05 > Instruments - 'Check Park Assist' Displayed
Instrument Panel Control Module: All Technical Service Bulletins Instruments - 'Check Park Assist'
Displayed
TSB 05-9-12
05/16/05
"CHECK PARK ASSIST" DISPLAYED IN MESSAGE CENTER - VEHICLES BUILT PRIOR TO
4/1/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built prior to 4/1/2005 and equipped with a
message center, may display a "Check Park Assist" message with no diagnostic trouble codes
(DTCs) present in the message center.
ACTION Reprogram the cluster to the latest calibration using WDS release B37.2 or higher.
Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050912A 2005 Expedition/Navigator 0.3 Hr.
Check For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With
12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14026 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 1192
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 1193
Backup Lamp Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 1194
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Battery Discharge Protection Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1198
View 151-1 (Engine Compartment)
The battery saver relay is part of the central junction box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Locations
Courtesy Lamp Relay: Locations
View 151-12 (Dash Panel)
The interior lamp relay is located in the instrument cluster and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay
Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Headlamp Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 1206
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 1207
Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Ignition Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 1208
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay > Page 1211
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay
Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Headlamp
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 1214
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 1215
Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Ignition
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 1216
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1220
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1221
Fog/Driving Lamp Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1222
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 1226
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 1227
Hazard Flasher Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 1228
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module >
Component Information > Application and ID
Headlamp Control Module: Application and ID
AUTOLAMPS
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 1235
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 1236
High Beam Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 1237
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1241
View 151-1 (Engine Compartment)
The horn relay is part of the central junction box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations
Interior Lighting Relay: Locations
View 151-12 (Dash Panel)
The interior lamp relay is located in the instrument cluster and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Electronic Park Brake Release Relay > Page 1249
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Electronic Park Brake Release Relay > Page 1252
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay
Parking Lamp Relay: Testing and Inspection Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 1255
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 1256
Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 1257
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 1262
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 1265
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 1268
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 1269
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 1270
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 1274
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 1275
Turn Signal Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 1276
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection > Page 1281
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection > Page 1285
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 1289
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 1290
Power Distribution Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 1291
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box
Relay Box: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1296
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1297
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1298
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1299
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1300
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1301
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1302
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Central Junction Box > Page 1303
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 1304
Relay Box: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 1305
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 1306
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 1307
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 1308
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Component Information > Locations > Page 1309
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Component Information > Locations > Page 1310
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Component Information > Application and ID > Central Junction Box
Relay Box: Application and ID Central Junction Box
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Component Information > Application and ID > Central Junction Box > Page 1315
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Component Information > Application and ID > Central Junction Box > Page 1316
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Component Information > Application and ID > Central Junction Box > Page 1317
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Component Information > Application and ID > Central Junction Box > Page 1318
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Component Information > Application and ID > Central Junction Box > Page 1319
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Component Information > Application and ID > Central Junction Box > Page 1320
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Component Information > Application and ID > Central Junction Box > Page 1321
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Component Information > Application and ID > Central Junction Box > Page 1322
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations
Body Control Module: Locations
VEHICLE SECURITY MODULE (VSM)
View 151-17 (RH A-Pillar)
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Body Control Module: Diagrams
VEHICLE SECURITY MODULE (VSM)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat
Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Removal and Installation
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
- Prior to the removal of the module, it is necessary to upload module configuration information to
the appropriate diagnostic equipment. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery.
2. NOTE: The module is accessed with the seat fully in the UP position.
Slide the driver seat module forward to remove it from the bracket.
3. Disconnect the connectors and remove the DSM.
4. CAUTION: Once the module is installed it is necessary to download the module configuration
information from the diagnostic tool into
the new module.
To install, reverse the removal procedure.
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Module (DSM) > Page 1332
Body Control Module: Service and Repair Vehicle Security Module
VEHICLE SECURITY MODULE
Removal
1. NOTE: Prior to removal of the vehicle security module, it is necessary to upload the module
configuration information to a diagnostic tool. This
information needs to be downloaded into the new module once installed.
Disconnect the battery.
2. Remove the pin-type retainer and the RH A-pillar lower trim panel.
3. Disconnect the 3 vehicle security module electrical connectors. 4. Remove the 2 screws and the
vehicle security module.
Installation
1. Position the vehicle security module and install the 2 screws. 2. Connect the 3 vehicle security
module electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type
retainer. 4. Connect the battery. 5. Reconfigure the VSM module. 6. Train the tire pressure
sensors. 7. Clear the DTCs. Repeat the self-test.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and
Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The Generation II (Gen II) torque based electronic throttle control (ETC) is a hardware and
software strategy that delivers an engine output torque (via throttle angle) based on driver demand
(pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to
control the throttle opening and engine torque. The ETC system replaces the standard cable
operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and
mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable cam
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: Eliminate cruise control actuators.
- Eliminate idle air control (IAC) valve.
- Better airflow range.
- Packaging (no cable).
- More responsive powertrain at altitude and improved shift quality.
It should be noted that the ETC system includes a warning indicator (wrench light) on the
instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and
may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a
DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The
redundant throttle position signals are required for
increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle,
decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing
voltage). During normal operation the negative slope TP signal (TP1) is used by the control
strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage.
- Signal return (ground).
- TP1 voltage with negative voltage slope (5-0 volts).
- TP2 voltage with positive voltage slope (0-5 volts).
Accelerator Pedal Position (APP) Sensors
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Operation > Page 1336
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts).
- 2 signal return (ground) circuits.
- APP1 voltage with negative voltage slope (5-0 volts).
- APP2 voltage with positive voltage slope (0-5 volts).
- APP3 voltage with positive voltage slope (0-5 volts).
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
fault. The PCM determines if a signal is incorrect
by calculating where it should be, inferred from the other signals. A value will be substituted for an
incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
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Operation > Page 1337
GEN II ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal
position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
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Operation > Page 1338
Since the IPC and main controller share the same processor, they are subject to a number of
potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly
monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of
the IPC and the main processor. If it determines that the IPC function is impaired in any way, it
takes appropriate Failure Mode and Effects Management (FMEM) actions.
Electronic Throttle Monitor Operation:
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Operation > Page 1339
Electronic Throttle Monitor Operation (Part 1)
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
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Operation > Page 1340
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position.
- Greater than or equal to 5% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on,
engine off.
- Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard-stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of Range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard-stop.
The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - General PCM Programming Procedures
Engine Control Module: 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.
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Controls - General PCM Programming Procedures > Page 1345
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
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Controls - General PCM Programming Procedures > Page 1346
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
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page
1347
View 151-1 (Engine Compartment)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views
Engine Control Module: Connector Views
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Page 1350
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Page 1354
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash
Electrically Erasable Programmable Read Only Memory (EEPROM)
Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The flash electrically erasable programmable read only memory (EEPROM) is contained in an
integrated circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including
calibration information specific to the vehicle, and is capable of being programmed or flashed
repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635
or P1639. The VID block in an existing PCM can also be tailored to accommodate various
hardware or parameter changes made to the vehicle since production. Failure to carry out this
procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An
incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the VIN, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and four wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block will display on the diagnostic tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again
to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other
enhanced diagnostic tools that may have programming capabilities available. Refer to the
manufacturer's user manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and will need programming. There are 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 is carried out if the old PCM is capable of communicating. This is done by
the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle.
The stored data can now be downloaded to the new PCM after it has been installed.
Manual data entry must be Carried out if the old module is damaged or incapable of
communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and
carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make
certain that all parameters are included. Failure to properly program tire size in revolutions per mile,
(rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or
MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built
Data Center for the information needed to manually update the VID block with the diagnostic tool.
Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M
technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for
As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the
Motorcraft homepage, use the search function to find the Module Programming or As Built Data.
For Ford and L-M technicians, check the Programmable Module Installation link on the PTS
website for quick Programmable Module data information by vehicle when using the WDS or New
Generation Star (NGS).
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash
Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 1357
Engine Control Module: Service and Repair Removal and Installation
POWERTRAIN CONTROL MODULE (PCM)
Removal and Installation
1. Disconnect the battery ground cable.
2. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
3. Disconnect the powertrain control module (PCM) electrical connectors. 4. Remove the 4 bolts
and the PCM.
- To install, tighten to 7 Nm (62 lb-in).
5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1361
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1362
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1363
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Description and Operation
EGR Control Module: Description and Operation
EGR SYSTEM MODULE (ESM)
Overview
EGR System Module (ESM)
The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional
DPFE system, however the various system components have been integrated into a single
component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake
manifold with a metal gasket that forms the measuring orifice. This arrangement increases system
reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to
the intake side of the EGR valve, the downstream pressure signal measures manifold absolute
pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a
traditional DPFE system.
The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional
tests that monitor various aspects of the EGR system operation.
First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405
P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403).
NOTE: EGR normally has large amounts of water vapor that are the result of the engine
combustion process. During cold ambient temperatures, under some circumstances, water vapor
can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to
prevent MIL illumination for temporary freezing, the following logic is used.
If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for
the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will
not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines
that the malfunction is no longer present, the EGR system will be enabled and normal system
operation will be restored.
If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor
is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the
malfunction has been detected on 2 consecutive driving cycles.
After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the
low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will
deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is
very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is
evaluated to determine the amount of EGR system restriction. If the differential pressure is below a
calibrated threshold, a low flow malfunction is indicated (P0401/P0406).
Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero
requested EGR flow to carry out the high flow check. If the differential pressure exceeds a
calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR
valve seat (P0402).
If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the
altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run
reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle
leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will
attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is
disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will
be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles
for the EGR monitor to be set to a ready condition.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 1372
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 1373
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal And Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable.
3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the
fuel tank filler pipe.
Disconnect the fuel pump driver module (FPDM) electrical connector.
4. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 1377
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1381
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1382
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1383
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1388
Air Bag Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1389
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1390
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed, erroneous DTCs will result.
The restraints control module (RCM) carries out the following functions:
- deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioners to remove slack from the safety belt.
- monitors the SRS for faults.
- illuminates the air bag indicator if a fault is detected.
- flashes the air bag indicator to indicate the lamp fault code (LFC) detected.
- communicates through the data link connector (DLC) the current or historical Diagnostic Trouble
Codes (DTCs).
- signals the instrument cluster module to activate a chime if the air bag indicator is not available
and another SRS fault exists.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the ON position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC. If an SRS fault exists, 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 DLC, to the scan tool. If the air bag indicator does not function, and the
system detects a fault condition, the RCM will signal the instrument cluster module to activate an
audible chime. The chime is a series of 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. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the front air bags and safety belt pretensioners in the event that the ignition circuit is lost or
damaged during impact. The backup power supply will deplete its stored energy approximately one
minute after the battery ground cable is disconnected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1391
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Removal
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for proper air bag supplemental restraint
system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision
in which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
All vehicles 1. Depower the system.
Vehicles with a center console 2. Remove the center console.
Vehicles with 60/40 front bench seat 3. Remove the 60 percent portion of the front bench seat.
4. Remove the nuts and the restraints control module (RCM) top bracket.
5. WARNING: Do not handle, move or change the original horizontal mounting position of the
restraints control module (RCM) while the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1392
RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in
the inadvertent deployment of the safety canopy and risk of personal injury.
Separate the RCM from the bracket. 1
Remove the nuts.
2 Separate the RCM from the bracket.
All vehicles
6. Disconnect the small restraints control module (RCM) electrical connector.
1 Push down to release the retaining tab.
2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector.
7. Disconnect the large RCM electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM,
disengaging the lever.
2 Pull out and disconnect the large RCM electrical connector.
Vehicles with 60/40 front bench seat 8. Remove the RCM.
Vehicles with a center console
9. Remove the RCM.
1 Remove the RCM bracket bolts.
2 Remove the RCM with bracket.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1393
Vehicles with a center console
1. WARNING: The tightening torque of the air bag restraints control module (RCM) bracket
retaining bolts is critical for correct system
operation.
Install the RCM. 1
Position the RCM with bracket.
2 Install the bolts.
All vehicles
2. Make sure the connector position assurance lever is in the full release position before attempting
to connect the connector.
3. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
Position the large RCM electrical connector into the RCM.
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and slight resistance is felt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1394
4. Connect the RCM electrical connector.
- Pivot the connector position assurance lever toward the RCM, drawing the connector in to the
RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
5. Connect the small RCM electrical connector.
Vehicles with 60/40 front bench seat
6. WARNING: The tightening torque of the air bag restraints control module (RCM) to bracket
retaining nuts is critical for correct system
operation.
Install the RCM. 1
Position the RCM to the bracket. While positioning the RCM onto the bracket, make sure the wire harness is positioned between the
RCM and the bracket shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 1395
2 Install the nuts.
7. Position the RCM top bracket and install the nuts.
Vehicles with a center console 8. Install the center console.
Vehicles with 60/40 front bench seat 9. Install the 60 percent portion of the front bench seat.
All vehicles 10. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 05-9-17 > May > 05 > Restraints/Instruments Can't Disable Seat Belt Chime
Seat Belt Control Module: Customer Interest Restraints/Instruments - Can't Disable Seat Belt
Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 05-9-17 > May > 05 > Restraints/Instruments Can't Disable Seat Belt Chime > Page 1404
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-9-17 > May > 05 >
Restraints/Instruments - Can't Disable Seat Belt Chime
Seat Belt Control Module: All Technical Service Bulletins Restraints/Instruments - Can't Disable
Seat Belt Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-9-17 > May > 05 >
Restraints/Instruments - Can't Disable Seat Belt Chime > Page 1410
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched
Window Seal: All Technical Service Bulletins Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1416
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1417
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1418
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1419
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-4 >
Jul > 06 > Body - Wind Noise From Around Outside Mirrors
Window Seal: All Technical Service Bulletins Body - Wind Noise From Around Outside Mirrors
TSB 06-13-4
07/10/06
WIND / WHISTLE NOISE AROUND OUTSIDE MIRRORS
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
ISSUE Some 2003-2005 Expedition / Navigator vehicles may exhibit wind / whistle noise around
the outside mirrors at speeds above 40 MPH (64 Km/h).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Inspect the foam strip located on the glass run where it contacts the front portion of the window
flange. This foam can sometimes be rolled over into the channel of the glass run so that the foam is
caught between the window flange and the glass run channel (Figure 1). In this case the foam
should be pulled from the channel and routed further outboard on the glass run to ensure it does
not get trapped again during installation.
a. To inspect for this condition the interior door trim panel and the outside door belt moulding need
to be removed, Workshop Manual (WSM), Section 501. Once the door trim and belt moulding has
been removed, simply pulling off the front glass run from the window channel to view the position of
the foam strip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-4 >
Jul > 06 > Body - Wind Noise From Around Outside Mirrors > Page 1424
2. On vehicles built before 11/19/2004, it may be necessary to place a small strip of sticky backed
foam, or plastic (which can be found in the Rotunda 164-R4900 Squeak and Rattle Repair Kit /
Cavity number 164-R4903) in the front portion of the horizontal cutline of the mirror (Figure 2 and
3). This will redirect the airflow in this location and eliminate the wind noise.
3. If the noise is still present, continue with normal diagnostics using WSM, Section 100-0.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061304A 2003-2005 0.5 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding One Door (Do Not Use With 23943A)
061304B 2003-2005 0.9 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding Both Doors (Do Not Use With 23943A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17682 12
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1430
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1431
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1432
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 07-10-5 >
May > 07 > Body - Front Door Window Scratched > Page 1433
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-4 >
Jul > 06 > Body - Wind Noise From Around Outside Mirrors > Page 1438
2. On vehicles built before 11/19/2004, it may be necessary to place a small strip of sticky backed
foam, or plastic (which can be found in the Rotunda 164-R4900 Squeak and Rattle Repair Kit /
Cavity number 164-R4903) in the front portion of the horizontal cutline of the mirror (Figure 2 and
3). This will redirect the airflow in this location and eliminate the wind noise.
3. If the noise is still present, continue with normal diagnostics using WSM, Section 100-0.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061304A 2003-2005 0.5 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding One Door (Do Not Use With 23943A)
061304B 2003-2005 0.9 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding Both Doors (Do Not Use With 23943A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17682 12
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1443
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB), in the engine compartment, RH
side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1444
Starter Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1445
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 1451
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 1452
Compressor/Pump Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 1453
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations
Suspension Control Module: Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1457
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1458
Suspension Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1459
Suspension Control Module: Service and Repair
Air Suspension Control Module
Removal and Installation
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery ground cable.
2. NOTE: The air suspension control module is mounted to the lower left side of the dash above
the parking brake control.
Disconnect the electrical connectors.
3. Pull back the dash padding to expose the module mounting nuts.
4. Remove the air suspension control module nuts.
5. 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 and pneumatic test be carried out.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Application and ID > Page 1464
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair
Control Module: Service and Repair
Four-Wheel Drive (4WD) Control Module
Removal and Installation
NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module
(PCM) and is not serviced separately.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations
Four Wheel Drive Selector Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 1473
View 151-1 (Engine Compartment)
The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1
located in the engine compartment. LH side, front.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High
Relay > Page 1476
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case
Low to High Relay
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case
Low to High Relay > Page 1479
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case
Low to High Relay > Page 1480
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case
Low to High Relay > Page 1481
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1486
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1487
Heated Glass Element Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1488
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 1493
View 151-1 (Engine Compartment)
The accessory delay relay is located in the central junction box, in the engine compartment, RH
side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 1494
Power Window Relay: Locations Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 1495
View 151-21 (Right Rear)
The quarter window open relay is located in the auxiliary relay box 2, behind trim panel, in loading
space, RH side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 1496
Power Window Relay: Locations Quarter Window Close Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 1497
View 151-21 (Right Rear)
The quarter window close relay is located in the auxiliary relay box 2, behind trim panel, in loading
space, RH side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Quarter Window Open Relay > Page 1500
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay
Power Window Relay: Testing and Inspection Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay > Page 1503
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay > Page 1504
Power Window Relay: Testing and Inspection Quarter Window Close Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay > Page 1505
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE PROCEDURE
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an
audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when
obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1516
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four parking aid module parameter identification displays (PIDs) for distance
information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1517
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select The Appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1518
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1519
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE PROCEDURE
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an
audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when
obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1525
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four parking aid module parameter identification displays (PIDs) for distance
information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1526
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select The Appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1527
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1528
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Outer/Inner Left
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Outer/Inner Left > Page 1531
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Outer/Inner Left > Page 1532
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 1535
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 1536
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 1537
Parking Assist Distance Sensor: Diagrams Parking Aid Ultrasonic Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Page 1538
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
Removal and Installation
All vehicles 1. Remove the rear bumper cover.
2. Remove the nuts and the foam absorber from the bumper cover.
Navigator
3. Remove the 2 ultrasonic sensors.
1 Disconnect the electrical connectors.
2 Release the locking tabs.
3 Remove the ultrasonic sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Page 1539
4. Remove the radar sensor.
1 Disconnect the electrical connector.
2 Remove the fasteners.
3 Remove the radar sensor.
Expedition 5. Remove the ultrasonic sensor(s).
1 Disconnect the electrical connector.
2 Release the locking tabs.
3 Remove the ultrasonic sensors.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Page 1540
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Sensor > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations > Page 1547
Pedal Positioning Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page
1550
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page
1551
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page
1552
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor >
Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 1560
Pedal Positioning Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 1563
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 1564
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 1565
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Driver Side
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Driver Side > Page 1570
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side
Power Door Lock Switch: Diagrams Driver Side
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side > Page 1573
Power Door Lock Switch: Diagrams Passenger Side
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 1574
Power Door Lock Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 1575
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1579
Power Mirror Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1580
Power Mirror Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1581
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1582
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
Removal and Installation
All vehicles 1. Remove the driver front door trim panel.
Navigator
2. Depress the locking tabs and remove the exterior mirror control switch.
Expedition
3. Remove the exterior mirror control switch.
1 Depress the locking tabs.
2 Remove the exterior mirror control switch.
All vehicles 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1587
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1588
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1589
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1590
Power Seat Motor Position Sensor: Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1591
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1592
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1593
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1594
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1595
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1598
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1599
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1600
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1601
Power Seat Motor Position Sensor: Diagrams Height Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1602
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 1607
Power Seat Switch: Locations Power Seat Switch
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 1608
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch
Power Seat Switch: Diagrams Power Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch > Page 1611
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch > Page 1612
Power Seat Switch: Diagrams Third Row Folding Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch
Power Seat Switch: Testing and Inspection Power Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1615
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1616
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1617
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1618
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1619
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1620
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1621
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1622
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1623
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1624
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1625
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1626
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1627
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1628
Power Seat Switch: Testing and Inspection Third Row Folding Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1629
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1630
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch > Page 1631
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way
Power Seat Switch: Service and Repair Seat Control Switch - 8-Way
SEAT CONTROL SWITCH - 8-WAY
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver side shown, passenger side similar.
1. Remove the affected seat and depower the SRS.
2. Pry to remove the two power seat knobs and remove the knobs.
3. Access and remove the front side shield screw.
4. Pull out from the bottom and rear side of side shield to release the three retainer clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1634
5. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors.
6. Remove the three screws and remove the power seat switch.
Installation
1. Install the power seat switch and install the three screws.
2. Connect the 8-way power seat and power lumbar switch electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1635
3. Push to install the three side shield retainers onto the seat frame.
4. Access and install the front side shield screw.
5. Install the two power seat knobs. 6. Install the affected seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1636
Power Seat Switch: Service and Repair Seat Control Switch - 6-Way
SEAT CONTROL SWITCH - 6-WAY
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver seat is shown, passenger is similar.
1. Remove the affected seat and depower the SRS.
2. Disconnect the 6-way power seat switch electrical connector.
3. Remove the recliner handle screw cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1637
4. Remove the recliner handle screw and the recliner handle.
5. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure
on both sides of the knob to remove.
Pull out to remove the lumbar knob.
6. Remove the screw from the side shield under the lumbar knob.
7. CAUTION: Use care not to scratch the side shield when removing the power seat knob.
Pry the power seat knob off.
8. Access and remove the front side shield screw.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1638
9. Pull to release the center retainer on side shield.
10. Pull to release the retainer clip on the rear of side shield. 11. Remove the side shield from the
seat.
12. Remove the two screws and remove the 6-way power seat switch from the side shield.
Installation
1. Install the 6-way power seat switch on the side shield and install the two screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1639
2. Push to install the rear side shield retainer on seat frame.
3. Push to install the middle side shield retainer on the seat.
4. Access and install the front side shield screw.
5. Install the 6-way power seat knob.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1640
6. Install the screw on the side shield under the lumbar knob.
7. Align and install the lumbar knob.
8. Install the recliner handle and install the screw.
9. Install the recliner handle cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1641
10. Connect the 6-way power seat switch electrical connector. 11. Install the affected seat and
repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1642
Power Seat Switch: Service and Repair Seat Control Switch - Third Row
SEAT CONTROL SWITCH - THIRD ROW
Removal and Installation
1. Partially remove the RH quarter trim panel for access to the third row power seat switch(es). 2.
Remove the retainer nuts on the back side of the power seat switch housing.
3. Disconnect the power seat switch electrical connectors.
4. Release the four locking tabs (two shown) on the affected switch, and remove the switch. 5. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate
Hazard Sensor > Component Information > Service and Repair
Power Trunk / Liftgate Hazard Sensor: Service and Repair
PINCH STRIP SWITCH
Removal and Installation
NOTE: Left side shown, right side similar.
1. Remove brake light.
- Remove the screws.
2. Disconnect the pinch strip electrical connector.
3. Remove the pinch strip.
1 Remove the pin-type retainers.
2 Remove the grommet and route the harness out of the vehicle.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 1649
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 1658
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 1659
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 1660
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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A/C - Climate Controlled Seats DTC B272C or B272D > Page 1703
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
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Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1715
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 >
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
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Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1719
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
View 151-28 (Driver Door)
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Component Information > Locations > Page 1723
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 1724
Seat Memory Switch: Testing and Inspection
SWITCH - MEMORY SET
Memory Set Switch
Remove the memory set switch.
Measure the resistance between the indicated terminals while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to
the calling pinpoint test.
NOTE: Refer to multimeter user's manual for testing diodes.
To check the memory set switch LED, connect the positive meter lead to terminal 7 and the
negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, install a new switch; otherwise, return to the
calling pinpoint test.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations
View 151-23 (Roof)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 1728
Sunroof / Moonroof Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 1729
Sunroof / Moonroof Switch: Testing and Inspection
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 1730
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch
View 151-32 (Liftgate)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 1735
View 151-32 (Liftgate)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 1736
View 151-23 (Roof)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 1739
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 1740
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front
View 151-26 (Driver Seat)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front > Page 1745
View 151-27 (Passenger Seat)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front > Page 1748
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Page 1749
Vacuum/Pressure Pump Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Page 1750
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Page 1751
Vacuum/Pressure Pump Switch: Service and Repair
LUMBAR CONTROL SWITCH
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Access and remove the front side shield screw.
3. Pull out from the bottom and rear side of side shield to release the three retainer clips.
4. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Page 1752
5. Pinch retainer in and push from the rear of power lumbar switch to remove the switch from the
side shield.
Installation
1. Install the power lumbar switch into the side shield.
2. Connect the 8-way power seat and power lumbar switch electrical connectors.
3. Push to install the three side shield retainers onto the seat frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump
Switch, Seats > Component Information > Diagrams > Page 1753
4. Access and install the front side shield screw. 5. Install the 40 percent seat and repower the
SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations > Page 1758
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 1762
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 1767
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor > Page 1770
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Stability Control Sensor Cluster
Removal and Installation
NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the
yaw rate sensor, stability control sensor cluster.
1. Remove the front floor console.
2. Remove the 2 bolts and the stability control sensor cluster.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Release Switch > Component Information > Service and Repair
Parking Brake Release Switch: Service and Repair
Removal and Installation
Column shift (Expedition only)
1. NOTE: The parking brake release switch is located on the steering column. It is serviced as an
assembly with the brake shift interlock.
Remove the brake shift interlock park brake release switch assembly.
Floor shift
2. Remove the floor shift selector lever. 3. Remove the screws, disconnect the electrical connector
and remove the switch.
All vehicles
4. To install, reverse the removal procedure.
^ Make sure the switch is correctly aligned with the extension on the shifter before installing the
screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations > Page 1780
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Removal and Installation
1. Disconnect the battery.
2. Remove the 2 bolts and the steering wheel rotation sensor.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations
View 151-24 (Centre Console)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 1787
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Right Front
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Right Front > Page 1792
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Right Front > Page 1793
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 1796
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 1797
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 1798
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor-Front
Wheel Speed Sensor-Front
Removal and Installation
1. NOTE: If equipped, turn the air suspension switch to the OFF position.
With the vehicle in NEUTRAL, position it on a hoist
2. Disconnect the wheel speed sensor electrical connector.
3. Remove the bolt and the retainers.
4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front > Page 1801
5. Remove the brake disc.
6. Remove the bolt and the front wheel speed sensor. 7. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front > Page 1802
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Removal and Installation
1. Remove the parking brake shoes.
2. Disconnect the wheel speed sensor wire from the retaining clips.
3. Remove the bolt and the rear wheel speed sensor. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 1806
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 1807
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Removal and Installation
NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the
yaw rate sensor, stability control sensor cluster.
1. Remove the front floor console.
2. Remove the 2 bolts and the stability control sensor cluster.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1813
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT
Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 1816
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
1817
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Description and Operation
Temperature Sensor (Gauge): Description and Operation
Temperature Gauge
The PCM receives the engine coolant temperature status through hardwired circuitry to the engine
coolant temperature (ECT) sensor. The instrument cluster receives the engine coolant temperature
data from the PCM through the SCP communication network. The instrument cluster
microprocessor monitors the engine coolant temperature data received from the PCM and
commands the temperature gauge indication with a corresponding movement of the pointer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch > Page 1826
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Deactivator Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Deactivator Switch > Page 1829
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 1832
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake
Deactivator Switch
BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH
The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control
deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the
brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens
and power is removed from the PCM.
On some applications the normally closed BPS, along with the normally open brake pedal position
(BPP) switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile
learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to
the PCM did not change states when they were expected to, a diagnostic trouble code P1572 can
be set by the PCM strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Page 1833
Brake Switch (Cruise Control): Service and Repair
SPEED CONTROL DEACTIVATOR SWITCH
Removal
1. NOTE: The speed control deactivator switch can only be adjusted once. If further adjusting is
necessary, install a new switch.
Remove the deactivator switch. 1
Disconnect the electrical connector.
2 Rotate the deactivator switch counterclockwise 45 degrees and remove it.
Installation
All vehicles
1. Release the plunger lock (if equipped).
- Turn the lock knob counterclockwise until the first click is felt.
2. Fully press the brake pedal.
3. Install the deactivator switch.
1 Position the deactivator switch in the bracket and rotate it clockwise 45 degrees.
2 Connect the electrical connector.
Vehicles equipped with a locking tab
4. NOTE: There should be an extra click heard when tugging on the brake pedal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Page 1834
Slowly release the brake pedal and tug it moderately once the pedal reaches the rest position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Speed Control Switch - With Remote Audio/Climate Control
Cruise Control Switch: Service and Repair Speed Control Switch - With Remote Audio/Climate
Control
SPEED CONTROL SWITCH - WITH REMOTE AUDIO/CLIMATE CONTROL
Removal and Installation
All vehicles 1. Remove the driver side air bag module.
Expedition
2. Remove the speed control switch.
1 Disconnect the electrical connector.
2 Remove the screws.
Navigator
3. Remove the horn switch.
1 Disconnect the electrical connector.
2 Remove the bolts.
4. Remove the speed control switch.
1 Disconnect the wiring harness locators.
2 Remove the screws.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Speed Control Switch - With Remote Audio/Climate Control > Page 1842
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Speed Control Switch - With Remote Audio/Climate Control > Page 1843
Cruise Control Switch: Service and Repair Speed Control Switch - Without Remote Audio/Climate
Control
SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROL
Removal and Installation
1. Remove the driver side air bag module.
2. Remove the speed control actuator switch.
1 Release the four (A) speed control actuator switch clips and remove the (B) speed control
actuator switch.
2 Disconnect the speed control actuator switch electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 1848
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component
Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1859
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1860
Ambient Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1861
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
Removal and Installation
Expedition
1. Remove the radiator sight shield.
1 Remove the pin-type retainers.
2 Remove the radiator sight shield.
All vehicles
2. Detach the ambient temperature sensor pin-type retainer.
3. Disconnect the electrical connector and remove the ambient temperature sensor. 4. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Service and Repair > Blower Motor Switch
Blower Motor Switch: Service and Repair Blower Motor Switch
BLOWER MOTOR SWITCH
Removal and Installation
1. Remove the climate control assembly. 2. Pull and remove the blower motor switch knob.
3. Release the clips and remove the blower motor switch. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Service and Repair > Blower Motor Switch > Page 1866
Blower Motor Switch: Service and Repair Blower Motor Speed Control
BLOWER MOTOR SPEED CONTROL
Removal and Installation
1. Remove the RH lower instrument panel insulator.
2. Remove the blower motor speed control.
1 Remove the screw.
2 Remove the blower motor speed control.
3 Disconnect the blower motor speed control electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Diagrams > In-Vehicle Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 1872
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Diagrams > Page 1873
In-Vehicle Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Service and Repair > In-Vehicle Temperature Sensor
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor
IN-VEHICLE TEMPERATURE SENSOR
Removal and Installation
1. Remove the screws and the instrument cluster finish panel.
- Disconnect the electrical connectors.
2. Disconnect the aspirator hose and the in-vehicle temperature sensor electrical connector.
3. Remove the screws and the in-vehicle temperature sensor. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Service and Repair > In-Vehicle Temperature Sensor > Page 1876
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity
Sensor
IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR
Removal and Installation
1. Remove the in-vehicle temperature and humidity sensor trim cover.
2. Disconnect the aspirator hose and the in-vehicle temperature and humidity sensor electrical
connector.
3. Remove the screws and the in-vehicle temperature and humidity sensor. 4. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart (Part 1)
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart (Part 2)
The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a
thermistor device in which resistance changes with temperature. The electrical resistance of a
thermistor decreases as the temperature increases, and the resistance increases as the
temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN
also connected to the ACET sensor, the varying resistance affects the voltage drop across the
sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET
sensor changes the voltage the PCM detects.
The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost (demist
performance, reduce A/C clutch cycling, etc.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Description and Operation > Page 1880
Evaporator Temperature Sensor / Switch: Service and Repair
AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR
Removal and Installation
1. Lower the glove compartment.
2. Remove the screw and disconnect the evaporator discharge air temperature sensor electrical
connector.
3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and
evaporator core housing. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component
Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component
Information > Diagrams > Page 1884
Humidity Sensor: Service and Repair
IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR
Removal and Installation
1. Remove the in-vehicle temperature and humidity sensor trim cover.
2. Disconnect the aspirator hose and the in-vehicle temperature and humidity sensor electrical
connector.
3. Remove the screws and the in-vehicle temperature and humidity sensor. 4. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1889
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1893
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1897
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. NOTE: For Expedition headlamp and dimmer switch removal, refer to Lighting and Horns.
Remove the instrument panel finish panel. Disconnect the electrical connectors.
2. Depress the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1906
Door Switch: Locations Door Ajar Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1907
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1908
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1909
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 1912
Door Switch: Diagrams Door Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 1913
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Page 1914
Door Switch: Service and Repair
DOOR AJAR SWITCH
Removal and Installation
1. Remove the door latch.
2. Remove the door ajar switch.
1 Release the door lock actuator locking tab.
2 Remove the door lock actuator.
3 Release the locking tab and remove the door ajar switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir
Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page 1919
Fuel Gauge Sender: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page 1920
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page 1921
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 1922
Fuel Gauge Sender: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 1923
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations > Page 1927
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Service and Repair
Ambient Light Sensor: Service and Repair
PHOTOCELL AND AMPLIFIER
Removal and Installation
All vehicles 1. Disconnect the battery ground cable.
Expedition
2. Remove the photocell and bezel from the defroster grille.
- Disconnect the electrical connector.
3. Remove the screws and the photocell and amplifier.
Navigator
4. Remove the defroster grille.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Service and Repair > Page 1932
5. Remove the screws and the photocell.
- Disconnect the electrical connector.
All vehicles 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 1936
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 1937
Backup Lamp Switch: Service and Repair
REVERSING LAMP
Removal and Installation
1. Remove the screws and the liftgate pull handle.
2. Remove the liftgate trim panel.
- Remove the water shield.
3. Release the tabs and remove the reversing lamp.
- Disconnect the reversing lamp.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 1941
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 1942
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 1943
Brake Light Switch: Service and Repair
BRAKE PEDAL POSITION (BPP) SWITCH
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the BPP switch.
1 Disconnect the electrical connector.
2 Remove the self-locking pin and the BPP switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Ajar Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Ajar Switch > Page 1948
Door Switch: Locations Door Ajar Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Ajar Switch > Page 1949
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Ajar Switch > Page 1950
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Ajar Switch > Page 1951
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Ajar Switch > Page 1954
Door Switch: Diagrams Door Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Ajar Switch > Page 1955
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Page 1956
Door Switch: Service and Repair
DOOR AJAR SWITCH
Removal and Installation
1. Remove the door latch.
2. Remove the door ajar switch.
1 Release the door lock actuator locking tab.
2 Remove the door lock actuator.
3 Release the locking tab and remove the door ajar switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection
Hazard Warning Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 1960
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 1961
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 1965
Headlamp Dimmer Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 1966
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 1967
Headlamp Dimmer Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 1968
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 1969
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 1970
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 1974
Headlamp Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 1975
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps
Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 1978
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 1979
Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 1980
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Page 1981
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
Removal and Installation
All vehicles 1. Disconnect the battery ground cable.
Expedition
2. CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel.
NOTE: Use a thin-bladed tool to remove the headlamp switch bezel assembly.
Remove the headlamp switch and bezel assembly. Disconnect the electrical connectors.
Navigator
3. Remove the headlamp switch and bezel assembly.
- Disconnect the electrical connectors.
4. Remove the screws, release the tabs and remove the headlamp switch.
All vehicles 5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
SWITCH - INTERIOR LAMP
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 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
View 151-14 (Steering Column)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 1988
Turn Signal Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 1989
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion
Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1992
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1993
Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1994
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1995
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Page 1996
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
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Component Information > Testing and Inspection > Page 1997
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2003
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2004
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-4 (Engine, Front)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2008
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2009
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
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Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor 1 > Page 2017
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2018
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
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2019
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
2026
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
2027
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
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2028
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
2032
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > CHT Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
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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 2035
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
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Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > Page 2036
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input
Fuel Level Sensor: Description and Operation Fuel Level Input
FUEL LEVEL INPUT
NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in
the tank and the sensor signal is provided as a communications network message by the
instrument cluster to the PCM.
The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP)
module or a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Fuel Level Input > Page 2041
Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Fuel Level Input > Page 2042
Fuel Level Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input > Page 2043
Mechanical Returnless Fuel Pump Module (FPM)
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Fuel Level Input > Page 2044
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Page 2045
Fuel Level Sensor: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Page 2046
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
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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 Rail Pressure (FRP) Sensor
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the pressure decreases. The varying resistance affects the voltage drop across the
sensor terminals and provides electrical signals to the PCM corresponding to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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> Fuel Rail Pressure (FRP) Sensor > Page 2051
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP
leak check monitor.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Operation > Fuel Tank Pressure (FTP) Sensor > Page 2056
Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Fuel Tank Pressure (FTP) Sensor > Page 2057
Mechanical Returnless Fuel Pump Module (FPM)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Operation > Fuel Tank Pressure (FTP) Sensor > Page 2058
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 2059
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect fittings from the fuel
vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect fittings from the fuel
pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the
removal procedure.
- Leak test the system.
- Carry out the evaporative emission repair verification drive cycle. See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
2063
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
2064
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand Alone/Non-integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange
Type MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases
as the temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
2065
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described above. However, one is located before the supercharger at the air cleaner for
standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in
the intake manifold. The IAT2 sensor located after the supercharger provides air temperature
information to the PCM to control border-line spark and to help determine intercooler efficiency.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 >
Page 2071
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2072
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2073
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 2080
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 2081
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 2082
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5.
Remove the EOT sensor. Discard the O-ring seal.
- To install, tighten to 21 Nm (15 lb-ft).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2087
Oxygen Sensor: Harness Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2088
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2089
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2090
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2091
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2092
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 2095
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 2096
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 2097
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2098
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage
according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in
the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the
PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during
closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater
by providing the ground when the proper conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor
(HO2S) electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2101
3. Using the special tool, remove the HO2S.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2102
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2103
3. Using the special tool, remove the catalyst monitor sensor.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch > Page 2108
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
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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 (DPFE) System > Page 2113
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 2114
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 2123
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set >
Page 2129
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 05-22-10 > Nov > 05 > Instruments - Outside
Temperature Display Inaccurate
Outside Temperature Display: All Technical Service Bulletins Instruments - Outside Temperature
Display Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2140
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2141
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor > Page 2144
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 2145
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2149
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2150
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2151
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2152
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2153
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information generated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor > Page 2158
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency
that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity,
the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor
generates a signal with a higher frequency. The PCM uses the frequency signal generated by the
VSS (and other inputs) to control such parameters as fuel injection, ignition control,
transmission/transaxle shift scheduling, and torque converter clutch scheduling.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 2164
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 2165
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2170
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2171
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2175
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2176
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2177
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2178
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel
Tank Pressure Transducer Sensor
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel
Tank Pressure Transducer Sensor > Page 2183
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor > Page 2186
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page
2187
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2191
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation > Fuel Rail Pressure Temperature (FRPT) Sensor
Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 2194
Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor
FUEL RAIL TEMPERATURE (FRT) SENSOR
Fuel Rail Temperature (FRT) Sensor
The FRT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation > Page 2195
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2199
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2200
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 IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in
place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a
conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts
off the electric fuel pump. Once the switch is open it must be manually reset before restarting the
vehicle. Refer to the Owner's Literature for the location of the IFS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2201
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3.
Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the two bolts and
the IFS switch.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set > Page 2210
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL
ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL
ON/DTC's P2106 and P2135 Set > Page 2216
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2217
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 2218
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor > Page 2221
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 2222
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
1 > Page 2229
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2230
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2231
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2235
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2236
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2237
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 2243
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 2244
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2250
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2251
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2252
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor > Page 2258
Impact Sensor: Locations Safety Canopy Sensor
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor > Page 2259
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor > Page 2260
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor > Page 2261
View 151-21 (Right Rear)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor > Page 2264
Impact Sensor: Diagrams Safety Canopy Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor > Page 2265
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Page 2266
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
For these vehicles, the SRS uses up to eight sensors. Within the RCM there can be up to three
safing sensors which are not separately serviced. The RCM will always have at least one safing
sensor for front impact. Two more safing sensors are used if the vehicle is equipped with safety
canopy modules. The RCM is mounted to the center tunnel beneath the console or bench seat. All
vehicles will have a front impact severity sensor that is located in the front-center of the vehicle,
mounted near the bottom of the hood latch support bracket. If the vehicle is equipped with safety
canopy modules, there are four additional side impact sensors external to the RCM. One front row
side impact sensor is located behind each of the front door interior trim panels. One second row
side impact sensor is located at the base of each C-pillar. Mounting orientation is critical for correct
operation of all impact and rollover sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Side Impact Sensor - Second Row
Impact Sensor: Service and Repair Side Impact Sensor - Second Row
SIDE IMPACT SENSOR - SECOND ROW
Removal
WARNING:
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The driver side is shown, the passenger side is similar.
- 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. Depower the system. 2. Remove the rear door scuff plate.
3. Separate the rear quarter trim panel.
1 Remove the safety belt anchor.
2 Pull out at the front of the rear quarter trim panel, releasing the retaining clips, allowing access to
the side impact sensor.
4. Remove the side impact sensor.
1 Remove the bolt.
2 Disconnect and remove the side impact sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Side Impact Sensor - Second Row > Page 2269
1. Make sure the second row side impact sensor tabs are aligned to the bracket.
2. Install the second row side impact sensor with bracket.
1 Align and insert the second row side impact sensor bracket locator pin to the opening in the
quarter panel sheet metal.
2 Install the bolt.
3 Connect the electrical connector.
3. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Install the rear quarter trim panel. 1
Align the rear quarter trim panel and push in, seating the retaining clips.
2 Install the safety belt anchor.
4. Install the rear door scuff plate. 5. Repower the system. 6. Check the active restraint system for
correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Side Impact Sensor - Second Row > Page 2270
Impact Sensor: Service and Repair Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
Removal
WARNING:
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Depower the system.
2. Remove the pin-type retainers and lower the front lower splash shield to access the front impact
severity sensor.
3. NOTE: The front impact severity sensor is mounted on the bottom of the hood latch support
bracket.
Remove the front impact severity sensor. 1
Remove the nut.
2 Disconnect and remove the front impact severity sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Side Impact Sensor - Second Row > Page 2271
1. CAUTION: If the hood latch support bracket or weld stud are damaged in any way that would
affect the way the front impact severity
sensor mounts to its original manufactured position, a new hood latch support bracket must be
installed.
NOTE: Make sure the hood latch support bracket and front impact severity sensor mating surfaces
are clean and debris free.
Position the front impact severity sensor. 1
Position the front impact severity sensor onto the hood latch support bracket stud.
2 While sliding the front impact severity sensor onto the stud, align the locator tabs to the hood
latch support bracket alignment holes.
2. Install the front impact severity sensor.
1 With the front impact severity sensor sitting flat up against the hood latch support bracket, install
the nut.
2 Connect the front impact severity sensor.
3. Position the front lower splash shield and install the pin-type retainers. 4. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Side Impact Sensor - Second Row > Page 2272
Impact Sensor: Service and Repair Side Impact Sensor - Front Row
SIDE IMPACT SENSOR - FRONT ROW
Removal
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON.
This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The driver side is shown, the passenger side is similar.
- 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. Depower the system. 2. Remove the front interior door trim panel on the side with the affected
side impact sensor.
3. Separate the weathershield enough to access the side impact sensor.
4. Remove the side impact sensor.
1 Remove the bolt.
2 Disconnect the electrical connector.
3 Remove the side impact sensor.
Installation
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Side Impact Sensor - Second Row > Page 2273
1. CAUTION: Always replace the J-clip retaining nut whenever installing a side impact sensor.
Align the locator tabs to the openings in the door.
2. CAUTION:
- The ground wire must be placed between the bolt head and the sensor. Never position the ground
wire between the J-clip retaining nut and the sensor.
- Always replace the J-clip retaining nut whenever installing a side impact sensor.
Install the side impact sensor. 1
Connect the electrical connector.
2 With the locator tabs aligned to the openings in the door, position the side impact sensor to the
door.
3 Position the ground wire between the bolt head and the sensor.
4 Install the bolt.
3. Position back the weathershield. 4. Install the front interior door trim panel on the side with the
affected side impact sensor. 5. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver > Page 2279
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Page 2280
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the supplemental restraint system (SRS), the driver and front outboard passenger safety
belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches indicate
to the restraints control module (RCM) whether the safety belts are connected or disconnected.
The RCM uses this information in determining the deployment rate of the dual-stage driver and
passenger air bag modules.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 2284
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 2285
Seat Sensor/Switch: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is mounted to a bracket attached to the inboard side of the seat
track. The seat track position sensor informs the restraints control module (RCM) of the driver seat
position. The RCM uses this information in determining the deployment rate of the dual-stage driver
air bag module.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 2286
Seat Sensor/Switch: Service and Repair
SEAT POSITION SENSOR
Removal
WARNING:
- Always wear safety glasses when repairing a supplemental restraint system (SRS) vehicle and
when handling an airbag 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
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Before removing the seat, position it to access the seat position sensor.
1. Position the seat to allow access to the fasteners. 2. Depower the system. 3. Remove the 40
percent driver front seat.
4. CAUTION: Make sure to remove all metal chips from the seat position sensor and the
surrounding areas after drilling out the rivet.
Remove the seat position sensor. 1
Disconnect the seat position sensor electrical connector.
2 Drill out the rivet.
3 Remove the seat position sensor.
Installation
1. CAUTION: Make sure to remove all metal chips from the seat position sensor and surrounding
areas after drilling out rivet.
Install the seat position sensor. 1
Position the seat position sensor to the seat, engaging the tab to the seat bracket.
2 Install the rivet.
3 Connect the seat position sensor electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 2287
2. Install the 40 percent driver front seat. 3. Repower the system. 4. Check the active restraint
system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2294
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2295
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 2299
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch > Page 2306
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 2310
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage
Loose
Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage
Loose > Page 2320
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height
Sensor Linkage Loose
Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor
Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height
Sensor Linkage Loose > Page 2326
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Page 2327
Ride Height Sensor: Service and Repair
Suspension Height Sensor
Removal and Installation
NOTE: Front shown, rear similar.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the LH
quarter trim panel. 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. Disconnect the sensor arm.
3. Remove and discard the nuts (front height sensor).
4. Remove and discard the bolts (rear height sensor).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Page 2328
5. Disconnect the electrical connector.
6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle.
To install, reverse the removal procedure. ^
Calibrate the height sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 2332
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 2336
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 2341
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 2342
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 2343
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 2344
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2353
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive. The operator of the vehicle controls. the position of the TCS.
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch
in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control
(TC) Switch - Column Shift
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift
Transmission Control (TC) Switch - Column Shift
Removal and Installation
NOTE: The Transmission Control (TC) switch is not replaceable. If a new TC switch is required,
install a new transmission selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control
(TC) Switch - Column Shift > Page 2359
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift
Transmission Control (TC) Switch - Floor Shift
Removal and Installation
NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a
new selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2363
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2364
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2365
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2366
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2367
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor > Page 2372
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 2375
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 2376
Transmission Speed Sensor: Service and Repair
Speed Sensors
NOTE: Only remove the affected sensor.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2381
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2382
Four Wheel Drive Selector Switch: Description and Operation
FOUR-WHEEL DRIVE (4WD) MODE SWITCH
Typical 4WD Switch
The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to
adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch
Power Window Switch: Locations Window Adjust Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2388
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2389
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2390
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2391
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2394
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2395
Power Window Switch: Diagrams Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2396
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2397
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2398
Power Window Switch: Diagrams Power Quarter Window Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2401
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2402
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2403
Power Window Switch: Testing and Inspection Power Quarter Window Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2404
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2405
Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2406
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2407
Power Window Switch: Testing and Inspection Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2408
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 2409
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
Removal and Installation
Navigator front 1. Lift up on the center console armrest.
2. Remove the center console window control switch panel.
- Remove the pin-type retainer.
3. Disconnect the electrical connectors and remove the window control switch.
- Release the locking tabs.
Expedition front and Expedition passenger rear
NOTE: Driver side Expedition shown, all others similar.
4. Remove the window control switch panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 2410
5. Disconnect the electrical connector(s) and remove the window control switch.
- Release the locking tabs.
Navigator passenger rear 6. Remove the rear door trim panel. 7. Remove the window control
switch from the door trim panel.
All vehicles 8. To install, reverse removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 2415
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2419
Windshield Washer Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2420
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2421
Windshield Washer Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2422
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2423
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2424
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2425
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Blade
Heater Switch > Component Information > Locations
View 151-33 (Climate Control System)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Blade
Heater Switch > Component Information > Locations > Page 2429
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2433
Wiper Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2434
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2435
Wiper Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2436
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2437
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 2443
Alignment: Specifications General Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 2444
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2445
Alignment: Description and Operation
Wheel Alignment Angles
The front caster and camber are adjusted by removing the lower arm-to-frame mounting bolts and
installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the
use of the front wheel spindle tie-rod. The rear camber is adjusted by removing the upper
arm-to-wheel knuckle mounting bolt and installing an adjuster kit to allow the wheel knuckle to be
adjusted in the arm slot. The rear toe is adjusted by the use of the rear toe link.
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Toe
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2446
Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
Ride Height
NOTE: Air suspension vehicles must be at trim prior to measuring the vehicle ride height.
Front Ride Height Measurement
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2447
Rear Ride Height Measurement
Wheel Track
Dogtracking
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2448
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 Km/h (40 mph), and can begin or be amplified when the
tire contacts pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces or tire imbalance. This condition is observed by the driver as small rotational
oscillations of the steering wheel.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to
center after a turn or the steering correction is completed.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the
steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20 degrees of steering wheel turn). Efforts may be said to be flat on center. ^
Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear
teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the
effort from the self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment
Alignment: Service and Repair Front Toe Adjustment
Front Toe Adjustment
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the
caster, camber or toe.
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the straight forward position using a suitable holding device.
3. NOTE: Do not allow the steering gear bellows to twist while rotating the spindle tie-rod.
Remove the clamp(s).
4. Loosen the nut(s).
^ Clean and lubricate the nut(s) and spindle tie-rod threads.
5. Rotate the spindle tie-rod(s). 6. Start the engine and center the steering wheel.
^ Recheck the toe settings and adjust if necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment >
Page 2451
7. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the
boot can occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Tighten the nut(s).
8. Install the clamp(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment >
Page 2452
Alignment: Service and Repair Camber and Caster Adjustment - Front
Camber and Caster Adjustment Front
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the
caster, camber or toe.
1. NOTE: New lower arm-to-frame mounting bolts must be installed with cam bolt kits for forward
bushing; and for rearward bushing), to allow for
adjustment of the arm in the frame slot. The vehicle should be supported by the frame to ease
movement of the lower arm in the slot.
Remove the nuts and bolts. ^
Discard the nuts and bolts.
^ Install the cam bolt kit(s) and snug the nut(s).
2. To adjust the caster and camber, refer to the above chart.
^ Adjustments that require moving the front and the rear of the lower arm should be made equally.
3. While holding the cam bolt, tighten the nut(s). 4. Check and, if necessary, adjust the front toe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment >
Page 2453
Alignment: Service and Repair Camber Adjustment - Rear
Camber Adjustment Rear
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear
camber or toe.
1. NOTE: Support the vehicle at the lower arm to ease the wheel knuckle movement in the upper
arm slot.
Measure and record the LH rear and RH rear camber angles.
2. Compare the recorded camber angles to the specifications. Refer to the Alignment
Specifications. 3. Determine desired camber adjustment (subtract the specified camber angle from
the measured camber angle). 4. Remove the rear wheel.
5. Mark a scribe line on the upper arm-to-wheel knuckle bolt head and upper arm.
6. Use the above table to determine the camber adjustment required.
^ Obtained by subtracting the specified camber angle from the measure camber angle.
7. Install a new upper arm-to-knuckle nut on the upper arm-to-knuckle bolt. 8. Position the upper
arm-to-knuckle bolt in the upper arm slot as required to adjust camber angle to the value obtained
in Step 6.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment >
Page 2454
9. Tighten the upper arm-to-knuckle nut.
10. Install the wheel and tire assembly. 11. Using the alignment equipment, verify the camber
adjustment. 12. Check and if necessary, adjust the rear toe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment >
Page 2455
Alignment: Service and Repair Rear Toe Adjustment
Rear Toe Adjustment
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear
toe.
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the straight forward position using a suitable holding device.
3. Loosen the nuts(s).
^ Clean and lubricate the nut(s) and rear toe link threads.
4. Rotate the spindle tie rod.
5. NOTE: Make sure the toe settings are not disturbed while tightening the nuts.
Tighten the nut(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Toe Adjustment >
Page 2456
Alignment: Service and Repair Ride Height Adjustments (Vehicle Dynamic Suspension)
Ride Height Adjustments
Special Tool(s)
Inflation and Deflation of the Air Suspension System
1. NOTE: Make sure that the air suspension switch is in the ON position.
NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this
procedure.
Turn the ignition switch to the ON position.
2. Connect the diagnostic tool to the Data Link Connector (DLC). 3. Select Air Suspension Control
Module under Active Command Mode. 4. Follow the diagnostic tool directions to lift or vent the front
or rear suspension.
Calibration
Ride Height Resetting
1. NOTE: Make sure that the air suspension switch is in the ON position.
NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this
procedure.
Turn the ignition to the OFF position. ^
Exit the vehicle, close all doors and allow the system to vent the vehicle down to kneel height
(approximately 45 seconds).
2. With the ignition in the ON position, shift the vehicle into DRIVE and then back to PARK.
^ Exit the vehicle, close all doors and allow the vehicle to pump to trim (approximately 45 seconds).
3. Measure the ride height. 4. Open the LF door. 5. Connect the diagnostic tool to the Data Link
Connector (DLC). 6. While outside of the vehicle, select the correct vehicle year, model and engine
type. 7. Select Vehicle Dynamic Module (VDM). 8. Using the active command mode, vent or lift the
vehicle to achieve the correct ride height. 9. Select the "Save Calibration Values (Store Ride
Height)" diagnostic tool command to calibrate the VDM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Description and Operation
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that
relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic
procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and
HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel
Pressure Test Kit #134-R0087 or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
.......................................................... 600 - 650 RPM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
AIR CLEANER INTAKE PIPE
Exploded View
Removal and Installation
1. Remove the air cleaner element.
2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air
cleaner intake pipe to release the air cleaner intake pipe
from the air cleaner assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2469
3. Remove the air cleaner intake tube assembly.
4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Exploded View
Removal and Installation
1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner
element from the air cleaner element tray.
3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure
to do so will result in unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Number One Cylinder: Locations
Item ......................................................................................................................................................
............................................................ Specification
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System - MIL ON/DTC
P0300-P0308/P0316
Spark Plug: Customer Interest Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System - MIL ON/DTC
P0300-P0308/P0316 > Page 2492
BASIC PART NO. CODE
12405 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's
Spark Plug: Customer Interest Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 2497
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 2498
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 2499
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-25-4 > Dec > 08 > Ignition
System - MIL ON/DTC P0300-P0308/P0316
Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-25-4 > Dec > 08 > Ignition
System - MIL ON/DTC P0300-P0308/P0316 > Page 2505
BASIC PART NO. CODE
12405 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2510
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2511
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2512
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2513
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2514
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2515
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2516
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2517
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2518
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2519
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 2520
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
Spark Plug: All Technical Service Bulletins Fuel System - MIL ON/Rough Idle/Long
Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 2525
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 2526
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 2527
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2533
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2534
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2535
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2536
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2537
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2538
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2539
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2540
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2541
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2542
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System
- Spark Plug Removal Instructions > Page 2543
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap
Spark Plug: Specifications Gap
Spark Plug Gap ...................................................................................................................................
.................................0.040 - 0.50 in (1.02 - 1.27 mm)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap > Page 2546
Spark Plug: Specifications Torque
Spark Plug Torque ...............................................................................................................................
.........................................................34 Nm (25 ft-lb)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2547
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
.................................................................... PZT-2FE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 PLUGS
Engine Ignition - RH
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Removal and Installation > Page 2550
Engine Ignition - LH
Exploded View
Removal and Installation
1. Remove the ignition coil-on-plug.
2. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Removal and Installation > Page 2551
Spark Plug: Service and Repair Spark Plug-Inspection
Spark Plug-Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or wont or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Service and Repair > Removal and Installation > Page 2552
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a Heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
GENERAL SPECIFICATIONS
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2556
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2557
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
GENERAL SPECIFICATIONS
Valves
Valve stem-to-guide clearance - intake
.......................................................................................................................... 0.020-0.045
mm(0.001-0.002 in) Valve stem-to-guide clearance - exhaust
........................................................................................................................ 0.069-0.094
mm(0.003-0.004 in) Valve head diameter intake
............................................................................................................................................
33.62-33.98 mm(1.324-1.338 in) Valve head diameter exhaust
................................................................................................................................... 37.32-37.68
mm(1.469-1.483 in) Valve face runout ................................................................................................
................................................................................ 0.05 mm (0.002 in) Valve face angle ..................
..............................................................................................................................................................
............. 45.5 degrees Valve seat width intake
..........................................................................................................................................................
1.2-1.4 mm (0.047-0.055in) Valve seat width exhaust
........................................................................................................................................................
1.4-1.6 mm (0.055-0.063in) Valve seat angle .....................................................................................
................................................................................................ 44.5-45.0 degrees Valve spring free
length ...................................................................................................................................................
..................... 55.7 mm (2.19 in) Valve spring compression pressure
................................................................................................. 350 N (79 lbs) ± 17.5 N(4 lbs) (a
42.04 mm (1.66in) Valve spring installed height ..................................................................................
............................................................................. 42.04 mm (1.66 in) Valve spring installed
pressure ..................................................................................................... 350 N (79 lbs) ± 17.5 N
(4 lbs) @ 42.04 mm (1.66 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations
Drive Belt: Locations
Accessory Drive
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2564
Drive Belt: Diagrams
Accessory Drive
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2565
Drive Belt: Description and Operation
Accessory Drive
The accessory drive system:
- has a single serpentine drive belt (6 ribs). - has 3 idler pulleys. - has an automatic belt tensioner. is not adjustable.
The accessory drive system provides power to operate components which power other systems.
These could include components such as the generator, power steering pump, and A/C
compressor. Each of these components is equipped with a pulley which is driven by the accessory
drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler
pulleys may be provided to facilitate belt routing and alignment. The automatic belt tensioner
maintains correct belt tension and compensates for component wear and changes in system load.
System load changes can be caused by the A/C compressor clutch engaging and disengaging, or
demand changes on other systems powered by the accessory drive belt. To maintain correct
operation of this stem, it is critical that the correct length drive belt be installed. The pulleys must
also be correctly aligned and kept clean.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Inspection and Verification
CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys be
lubricated as potential damage to the belt material and tensioner damping mechanism will occur.
Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
Visual Inspection Chart
3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, power steering
cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered
acceptable. If damage exceeds the acceptable limit or
any chunks are found to be missing from the ribs, a new belt must be installed.
Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be
considered acceptable. If cracks exceed this standard, install a new belt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2568
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
6. The condition of the V-ribbed drive belt should be compared against the illustration and
appropriate action taken.
1. Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new
belt is not required. 2. Longer deposit areas building up to 50 percent of the rib height. This is not
considered a concern but it can result in excessive noise. If noise is
apparent, install a new belt.
3. Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a
new belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt. 8. If the concern is not visually evident, verify the symptom and
GO to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2569
Drive Belt: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2570
Drive Belt: Component Tests and General Diagnostics
Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of
a damaged or an incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on
an accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start-up and shut down or during very rapid
engine acceleration and decelerations, such as: ^
wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions.
^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual
transmissions.
These special short-term transient events are expected, and are due to the higher system inertial
required to meet the electrical and cooling demands on today's vehicle systems. Constant or
re-occurring drive belt squeal can occur under these conditions: ^
if the A/C discharge pressure goes above specifications: the A/C system is overcharged.
- the A/C condenser core airflow is blocked.
^ if the A/C OFF equalized pressure (the common discharged and suction pressure that occurs
after several minutes) exceeds specifications.
^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories
should be rotatable by hand in the unloaded condition, if not, inspect the accessory.
^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has
been exposed to fluid contamination during vehicle operation, such as leaks from the power
steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with
clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a
localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt
and pulleys should be washed with soap and water immediately (prior to starting the engine), and
rinsed with clean water.
^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive
belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will
release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.
^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.
Incorrect Drive Belt Installation
CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can
cause the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt
tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive
belt.
Incorrect Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2571
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the
accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur.
Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking
condition exists, proceed with the following: ^
Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface.
If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out
of position. This will result in chirp and squeal noises.
^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any
interference that would prevent the component from mounting correctly. Correct any interference
condition and recheck the accessory drive belt tracking.
^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware
to specification. Recheck the accessory drive belt tracking.
Belt Tensioner-Mechanical
The only mechanical check that needs to be made is a check for tensioner stick grab or bind. 1.
With the engine OFF, check routing of the accessory drive belt.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension
on the belt and detach the accessory drive belt in the area of the tensioner.
3. Using the suitable, commercially available serpentine belt tensioner release tool, move the
tensioner from its relaxed position, through its full
stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make
sure that there is tension on the tensioner spring.
4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
Install a new accessory drive belt tensioner if
necessary.
5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks. Install a new accessory drive
belt tensioner as necessary.
6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner
dynamically. If the accessory drive belt tensioner
does not meet the above criteria, install a new tensioner.
Belt Tensioner-Dynamics
The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine
running, observe the accessory drive belt tensioner movement. The accessory drive tensioner
should move (respond) when the air
conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory
drive belt tensioner movement is excessive without air conditioning clutch cycling or engine
acceleration, check belt ride-out. Excessive belt ride-out (uneven depth of grooves in the belt) can
cause excessive accessory drive belt tensioner movement. Check ride-out condition by installing a
new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory
drive belt tensioner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2572
Drive Belt: Service and Repair
Accessory Drive
Removal
1. Rotate the drive belt tensioner clockwise and remove the drive belt.
Installation
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component
Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
AIR CLEANER INTAKE PIPE
Exploded View
Removal and Installation
1. Remove the air cleaner element.
2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air
cleaner intake pipe to release the air cleaner intake pipe
from the air cleaner assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component
Information > Service and Repair > Page 2578
3. Remove the air cleaner intake tube assembly.
4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Exploded View
Removal and Installation
1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner
element from the air cleaner element tray.
3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure
to do so will result in unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter
Fluid Filter - A/T: Service and Repair Transmission Fluid In-Line Filter
Transmission Fluid In-Line Filter
Material
Transmission Fluid In-line Filter with a OTA cooler
NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^
If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a
new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If equipped, remove the bolts and the skid plate.
3. Remove the section of the rubber hose and steel line as illustrated.
^ Clean and de-burr the end of the steel line.
4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of
the ferrule nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter > Page 2589
Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube.
Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the
connector.
5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of
fluid flow through the filter. The filter must
be installed in the fluid cooler return line with the red arrow on the filter pointing away from the
transmission fluid cooler and toward the transmission (the return line has fluid coming out of the
cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal
transmission damage.
CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater
than 60 degrees.
Using a suitable length of hose install the filter. Tighten the hose clamps.
6. Clean a section of the transmission fluid pan and install the sticker.
7. If equipped, install the skid plate and the bolts. 8. Fill the transmission with clean automatic
transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Transmission Fluid In-line Filter without a OTA cooler
NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^
If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a
new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter > Page 2590
2. Remove the cooler tubes retainers.
3. Remove the section of the steel tube as illustrated.
^ Clean and de-burr the end of the steel tubes.
4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of
the ferrule nut.
Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes.
Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the
connector.
5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of
fluid flow through the filter. The filter must
be installed in the fluid cooler return line with the red arrow on the filter pointing away from the
transmission fluid cooler and toward the transmission (the return line has fluid coming out of the
cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal
transmission damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter > Page 2591
CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater
than 60 degrees.
Using a suitable length of hose install the filter. Tighten the hose clamps.
6. Install one cooler tube retainer as illustrated.
7. Secure the cooler tubes together with a tie strap.
8. Clean a section of the transmission fluid pan and install the sticker. 9. Fill the transmission with
clean automatic transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter > Page 2592
Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Material
Removal
CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use
of these products could cause internal transmission components to fail; this will effect the operation
of the transmission. Use of a fluid other than specified could result in transmission failure.
NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major
repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will need to be
removed for repair. The transmission fluid needs to be changed if evidence of fluid contamination is
found.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain transmission fluid.
^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the
bolts.
3. Remove the transmission fluid pan and transmission fluid pan gasket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter > Page 2593
4. Pull down evenly and remove the transmission fluid filter and seal.
5. Clean and inspect the transmission fluid pan, gasket and magnet.
Installation
1. CAUTION: If installing a new filter and the seal remains in the main control bore, carefully use a
small screwdriver to remove the seal. Use care
not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
Install a new fluid filter and seal as required.
2. Position the pan magnet into the transmission fluid pan.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Transmission Fluid In-Line Filter > Page 2594
3. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket. 1
Position the transmission fluid pan and gasket.
2 Install the transmission fluid pan bolts.
4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7 liters (5
quarts).
Fill the transmission to the correct level with clean automatic transmission fluid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Oil Filter: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2607
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2608
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2609
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Oil Filter: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page
2615
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page
2616
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page
2617
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 2627
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 5 (2005))
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 2628
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 5 (2005))
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 5 (2005))
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
2634
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 5 (2005))
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
2635
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 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling
Heater Hose: Service and Repair Heater Hose Coupling
HEATER HOSE COUPLING
Remover, Heater Hose Inlet Tube
Special Tool(s)
Disconnect
1. WARNING: The engine must be off, fully cool and the cooling system fully depressurized before
attempting to disconnect any heater
water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid
escaping out of the engine cooling system.
Depressurize the engine cooling system.
2. Push the heater water hose toward the tube to fully expose the locking tabs.
3. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must
be perpendicular to and on the highest point of the
coupling.
Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to
assist in the removal.
Pull the heater water hose away from the heater core tube.
5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling > Page 2638
7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer.
Connect
1. Clean the tubes and lubricate with MERPOL(R) meeting Ford specification ESE-M99B144-B or
plain water.
2. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect
coupling housing.
3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the
coupling is fully engaged by lightly pulling on the heater water hose.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling > Page 2639
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE
Removal
CAUTION: To avoid refrigerant loss, clearly differentiate the auxiliary heater lines from the auxiliary
refrigerant lines before beginning this procedure.
NOTE:
- The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary
heater inlet line and outlet line are each installed from the factory as one piece assemblies. The
replacement parts are supplied as separate kits containing multiple piece lines for ease of
installation.
- The following procedure can be used to remove and install one of, or both the auxiliary heater
inlet line and auxiliary heater outlet line. If only one auxiliary heater line is to be removed and
installed, cut or disconnect only the desired line at the specified points within the procedure.
1. Drain the engine coolant. 2. Remove the RH quarter trim panel.
3. Detach the auxiliary heater lines.
1 Disconnect the heater hose(s).
2 Remove the bolts.
3 Remove the line bracket.
4. Remove the spare tire. 5. Raise the vehicle. 6. Remove the RH front wheel. 7. Remove the RH
fender splash shield.
8. NOTE: If installing only one auxiliary heater line, disconnect only the desired line.
Disconnect the heater hose(s).
9. Remove the muffler.
10. Remove the RH catalytic converter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling > Page 2640
11. Remove the three bolts and the heat shield.
12. Remove the bolts.
13. Remove the nut and the line bracket.
14. Remove the bolt and the heat shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling > Page 2641
15. Remove the nuts and the remaining line brackets.
16. NOTE: If installing only one auxiliary heater line, cut only the desired line.
Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using
a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s).
17. Remove the auxiliary heater line(s) in three separate pieces.
Installation
1. Partially lower the vehicle.
2. Attach the rear portion of the auxiliary heater lines.
1 Connect the heater hoses.
2 Install the line bracket.
3 Install the bolts.
3. Install the front auxiliary heater line(s) and connect the heater hose(s).
- Clean and lubricate the heater hoses with plain water only if needed.
4. Raise the vehicle.
5. NOTE: Loosely connect, but do not tighten, the fittings.
Install the middle auxiliary heater line(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling > Page 2642
6. Starting from the rear of the vehicle, install the first three line brackets. 7. Tighten the middle
auxiliary heater line fittings. 8. Inspect the auxiliary heater lines for correct installation. Loosen,
reposition and tighten as needed.
9. Install the heat shield and the bolts.
10. Install the heat shield and the bolts. 11. Install the RH catalytic converter. 12. Install the muffler.
13. Partially lower the vehicle.
14. Install the heat shield bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hose Coupling > Page 2643
15. Install the line bracket. 16. Lower the vehicle. 17. Install the spare tire. 18. Install the RH
quarter trim panel. 19. Fill the engine coolant level.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair
Hose/Line HVAC: Service and Repair
COMPRESSOR MANIFOLD AND TUBE ASSEMBLY
Removal and Installation
NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
All vehicles 1. Recover the refrigerant. 2. Disconnect the negative and positive battery cable.
3. Disconnect the electrical connector.
4. Disconnect the pressure cutoff switch electrical connector.
5. Remove the nut and disconnect the A/C fitting.
- Discard the O-ring seal.
Vehicles with auxiliary A/C
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Page 2647
6. Remove the nut and disconnect the auxiliary A/C line fitting.
- Discard the O-ring seal.
All vehicles
7. Remove the nut and disconnect the A/C fitting.
- Discard the O-ring seal.
8. Loosen the bolt and remove the compressor manifold and tube assembly.
- Discard the O-ring seals.
9. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
10. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line
Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure
Line
Power Steering Pump to Steering Gear Pressure Line 4x4
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
All vehicles
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. Remove the engine cooling fan. 3. Remove the power steering pump pulley.
4. Disconnect the pressure line-to-pump fitting.
^ Discard the Teflon seal.
^ Allow the fluid to drain into a suitable container.
5. Remove the 2 bolts and the oil drip shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2652
6. Remove the pressure line bracket-to-crossmember bolt.
7. Disconnect the pressure line from the frame rail retainers.
8. Remove the pressure line bracket-to-engine nut.
Expedition vehicles
9. Disconnect the pressure sensor electrical connector and the wiring harness retainer, if equipped.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2653
10. Remove the steering line clamp plate bolt and the pressure line.
^ Discard the O-ring seal.
11. To install, reverse the removal procedure.
^ Using the special tool, install a new Teflon seal on the pressure line-to-pump fitting.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2654
Power Steering Line/Hose: Service and Repair Power Steering Fluid Cooler to Power Steering
Fluid Reservoir Return Hose
Power Steering Fluid Cooler to Power Steering Fluid Reservoir Return Hose
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
All vehicles
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. With the vehicle in NEUTRAL, position the vehicle on a hoist.
Early build vehicles
3. Remove the 3 reservoir bolts.
4. Disconnect the clamp and remove the return line.
^ Allow the fluid to drain into a suitable container.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2655
5. Disconnect the hose from the retainer clips.
Late build vehicles
6. Disconnect the clamp and remove the return line.
^ Allow the fluid to drain into a suitable container.
All vehicles
7. Disconnect the clamp and remove the return line.
8. Disconnect the hose from the frame rail retainer and remove the hose. 9. To install, reverse the
removal procedure.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2656
Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose
Steering Gear to Fluid Cooler Return Hose
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
All vehicles
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. With the vehicle in NEUTRAL, position the vehicle on a hoist.
Navigator vehicles
3. Remove the pushpins and the deflector shield.
All vehicles
4. Disconnect the clamp and remove the return hose.
^ Allow the fluid to drain into a suitable container.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2657
5. Remove the 2 bolts and the oil drip shield.
6. Remove the steering line clamp plate bolt.
7. Disconnect the frame rail retainers and remove the return line. 8. To install, reverse the removal
procedure.
^ Install a new O-ring seal.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Cooling System Capacity
Base Radiator Without Aux Rear Heat ................................................................................................
................................................................ 19.4 quarts (18.4 liters) With Aux Rear Heat ......................
............................................................................................................................................... 20.7
quarts (19.6 liters)
Heavy Duty Trailer Tow Without Aux Rear Heat .................................................................................
............................................................................... 19.7 quarts (18.6 liters) With Aux Rear Heat .......
..............................................................................................................................................................
20.9 quarts (19.8 liters)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 2663
Coolant: Fluid Type Specifications
Coolant Types
Motorcraft Premium Gold Engine Coolant (yellow color). VC-7-A (US, except CA, OR and NM)
VC-7-B (CA, OR and NM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
.......................................................... 13.1L (13.9 Qt)
Note: Approximate capacity specifications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 2668
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Fluid Type ............................................................................................................................................
............................................... MERCON XT-2-QDX
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26
Fluid - A/T: Service and Repair Automatic Transmission - 6HP26
Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler - Backflushing and Cleaning
Material
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the cooler lines and install a new cooler before placing the transmission in use.
1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is
indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines.
3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting
them to the cleaner.
Connect the cleaner pressure and return lines appropriately. 1
Connect the pressure line to the fluid cooler inlet tube.
2 Connect the return line to the fluid cooler outlet tube.
3 Place the outlet end of the return line in the fluid tank reservoir.
4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system.
Switch the fluid pumps on. Allow the fluid to circulate a minimum of five minutes.
5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7.
Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove
the rubber hoses from the fluid cooler tubes.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Material
Drain
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2671
2. Remove the fluid pan drain plug and allow the fluid to drain.
Refill
1. Install the fluid pan drain plug.
^ Tighten to 8 Nm (71 inch lbs.).
2. Remove the fluid fill plug located on the RH rear side of the case, near the transmission
electrical connector.
3. CAUTION: The use of any other transmission fluid than specified can result in the transmission
failing to operate in a normal manner or
transmission failure.
Fill the transmission. ^
Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid
fill hole. Stop when the fluid runs out of the bottom of the hole.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2672
4. Install the fluid fill plug located on the RH rear side of the case, near the transmission electrical
connector. 5. Start the engine. Move the transmission range selector lever through all the gear
ranges, checking for engagements. 6. With the engine idling (600 - 750 rpm) in PARK and the
transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the
transmission fluid level.
7. If more fluid is needed, remove the fluid fill plug on the side of the case and fill with clean
automatic transmission fluid until the fluid runs out of
the bottom of the hole.
Transmission Fluid Level Check
Transmission Fluid Level Check
Fluid Level Check
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate
reading.
NOTE: The transmission fluid temperature must not be allowed to exceed 50°C (122°F) when
checking the fluid level. The fluid temperature should be between 30°C - 50°C (86°F - 122°F)
closer to 50°C (122°F) when checking the fluid level.
This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the
transmission operation and can result in transmission failure. Under normal circumstances, the fluid
level should not be checked during normal maintenance. If the transmission starts to slip, shifts
slowly or shows signs of fluid leaking, the fluid level should be checked.
1. With the transmission in P (PARK), the engine at idle (600 - 750 rpm) and foot pressed on the
brake, move the range selector lever through each
gear and allow engagement of each gear. Place the transmission range selector lever in the P
position.
2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the fluid fill plug
located on the side of the transmission case. 4. Partially add fluid until fluid starts to come out. Wait
until the fluid stops or just drips from the hole. 5. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.).
High Fluid Level
CAUTION: A fluid level that is too high can cause the fluid to become aerated due to the churning
action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid
from the vent tube and Possible transmission failure.
If an overfill reading is indicated, drain and refill the transmission.
Low Fluid Level
A low fluid level can result in poor transmission engagement, slipping or failure. This may also
indicate a leak in one of the transmission seals or
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2673
gaskets.
Adding Fluid
CAUTION: The use of any other type of transmission fluid than specified can result in transmission
failure.
If fluid must be added, add fluid in 0.5 liter (1/2 quart) increments through the fluid fill plug. Do not
overfill the fluid. For fluid type, refer to the specification chart.
Fluid Condition Check
1. Check the fluid level. 2. Remove the fluid fill plug and allow the fluid to drip onto a facial tissue
and examine the stain.
3. NOTE: The transmission fluid could be two different colors. The factory fill fluid is clear. The
replacement fluid is red.
Observe the color and the odor. The color under normal circumstances should be dark reddish or
clear, not black or have a burnt odor.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further
inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The
engine cooling system should also be inspected at this time. 6. If fluid contamination or
transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission
must be disassembled
and completely cleaned. This includes the torque converter and fluid cooler tubes. A new oil-to-air
cooler must be installed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2674
Fluid - A/T: Service and Repair Automatic Transmission - 4R70E/4R75E
Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
Material
1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The
use of these products could cause internal
transmission components to fail; this will effect the operation of the transmission.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to
make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush
equipment if flow is weak or contaminated.
2. If equipped, remove and discard the transmission fluid in-line filter. 3. To aid in attaching the
cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the
transmission end of the steel
transmission cooler lines as described below. ^
Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line).
^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the
outlet end of this hose in the tank reservoir.
4. Turn on the pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and
off will help dislodge contaminants in cooler
system).
5. Switch off the pump and disconnect the pressure hose from the transmission cooler return line.
6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler
return line) until all fluid is removed. 7. Remove the rubber return hose from the remaining steel
cooler line.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Special Tool(s)
Material
Draining, all vehicles using a suitable flush and fill machine
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2675
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for normal
or severe duty fluid maintenance.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to
change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid
cooler tube after the fluid cooler on the cooler return line. This will
help remove any foreign material trapped in the fluid coolers.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the
engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F),
check and adjust the transmission fluid
level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until
the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Draining, all vehicles not using a suitable flush and fill machine
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan. 4. Do not remove the fluid filter. It
is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Clean and inspect the transmission fluid pan, transmission fluid gasket and magnet. 6.
Thoroughly flush the cooler tubes.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2676
Refill
1. Position the magnet into the transmission fluid pan.
2. NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket. 1
Position the fluid pan with the gasket in place.
2 Install the bolts.
3. CAUTION: The use of any other transmission fluid can result in the transmission failing to
operate in a normal manner or transmission failure.
Fill the transmission. ^
Add 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the fluid filler
tube.
4. Start the engine. Move the transmission range selector lever through all the gear ranges,
checking for engagements. 5. With the engine running and the transmission at normal operating
temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid
level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until
the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Transmission Fluid Level Check
Transmission Fluid Level Check
CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the DO
NOT DRIVE mark or internal failure could result.
NOTE: If vehicle has been operated for an extended period of time at highway speeds, in city
traffic, in hot weather or when pulling a trailer, the fluid needs to cool down to obtain an accurate
reading.
NOTE: The fluid level reading on the indicator will differ from operating and ambient temperatures.
The correct reading should be within the normal operating temperature range.
Under normal circumstances, the fluid level should be checked during normal maintenance. If the
transmission starts to slip, shifts slowly or has signs of fluid leaking, the fluid level should be
checked.
1. With the transmission in (P) PARK, the engine at idle, foot pressed on the brake, move the range
selector lever through each gear and allow
engagement of each gear. Place the range selector lever in the PARK position.
2. Wipe the fluid level indicator cap and remove the indicator. 3. Wipe the indicator with a clean
cloth.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Automatic
Transmission - 6HP26 > Page 2677
4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator.
The fluid level should be within the normal operating temperature range.
High Fluid Level
A fluid level that is too high may cause the fluid to become aerated due to the churning action of
the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the
vent tube and Possible transmission malfunction and/or damage. If an overfill reading is indicated
drain and refill the transmission.
Low Fluid Level
A low fluid level could result in poor transmission engagement, slipping, malfunction and/or
damage. This could also indicate a leak in one of the transmission seals or gaskets.
Adding Fluid
CAUTION: The use of any type of transmission fluid other than specified could result in
transmission malfunction and/or damage.
If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not
overfill the fluid. For fluid type, refer to the General Specifications chart.
Fluid Condition Check
1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances
should be dark reddish, not brown or black or have a burnt odor. 3. Hold the fluid level indicator
over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If
evidence of solid material is found, the transmission fluid pan should be removed for further
inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The
engine cooling system should also be inspected at this time. 6. If fluid contamination or
transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission
must be disassembled
and completely cleaned. This includes the torque converter, coolers and cooler lines.
7. Carry out diagnostic checks and adjustments; refer to Diagnosis By Symptom.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Front Differential Fluid Capacity Ford 8.8 Inch Ring ............................................................................
....................................................................................................... 3.6 pints (1.7 liters) 0.38 in
(9.56mm) below bottom if differential housing fill hole.
Rear Differential Fluid Capacity Ford 9.75 Inch Ribbed Cover Conventional.......................................
..............................................................................................................................................................
...... 4.25 pints (0.9 in [23mm] below fill hole)
Traction-Loc .........................................................................................................................................
.................................. 4.25 + 4oz Friction Modifier * (0.9 in [23mm] below fill hole)
Smooth Cover Conventional.................................................................................................................
.......................................................................................... 4.25 pints (0.9 in [23mm] below fill hole)
Traction-Loc .........................................................................................................................................
.................................. 4.25 + 4oz Friction Modifier * (0.9 in [23mm] below fill hole)
*Install Friction Modifier in axle before installing lubricant.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 2682
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Front Differential Motorcraft SAE 80W-90 Premium Rear Axle Lubricant
............................................................................................................................... XY-80W90-QL
Rear Differential Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant
............................................................................................................ XY-75W140-QL Additive
Friction Modifier ...................................................................................................................................
.......................................................... XL-3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 2687
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page
2688
Fluid - Transfer Case: Service and Repair
Transfer Case Draining and Filling
Special Tool(s)
Material
1. Remove the drain plug and drain the fluid. Clean the drain plug and the drain plug area. Apply
thread sealant to the drain plug threads, then install
the drain plug.
2. Clean the area around the fill plug. Remove the fill plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page
2689
3. CAUTION: Incorrect fluid fill can result in transfer case failure.
Using the special tool, fill the transfer case to specification. ^
The fluid must be just below the fill plug hole. Fill the case until the fluid slowly flows over the fill
plug threads. Clean the fluid from the fill plug area.
4. Apply thread sealant to the fill plug threads, then install the fill plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Engine Oil: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2698
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2699
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2700
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Engine Oil: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2706
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2707
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2708
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 6.6L (7.0 Qt)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 2711
Engine Oil: Fluid Type Specifications
Engnie Oil
U.S. ............................................................................................................................... Motorcraft
SAE 5W-20 Premium Synthetic Blend XO-5W20-QSP Canada
................................................................................................................. Motorcraft SAE 5W-20
Super Premium Mortor Oil CXO-5W20-LSP12
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2716
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 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications
Power Steering Fluid: Capacity Specifications
Power Steering Fluid Capacity ............................................................................................................
....................................................2.7 pints (1.3 liters)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications > Page 2719
Power Steering Fluid: Fluid Type Specifications
Power Steering
........................................................................................................................MERCON
Multi-Purpose Transmission Fluid XT-2-QDX
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Customer Interest for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor Cooling Performance
Refrigerant: Customer Interest A/C - Hooting/Whistling Noise/Poor Cooling Performance
TSB 05-4-11
03/07/05
NOISE FROM A/C OR INSUFFICIENT A/C COOLING
FORD: 2004-2005 Expedition
LINCOLN: 2004-2005 Navigator
ISSUE Some 2004-2005 Expedition/Navigator vehicles built between 04/01/2004 and 9/26/2004,
may exhibit a hoot or whistle noise inside the passenger compartment, coming from the A/C
system. The vehicle may also exhibit insufficient A/C cooling. This may be due to low A/C
refrigerant charge from the factory.
ACTION If normal diagnostics do not point to a system leak, evacuate and recharge the A/C
system. Charge the system to 40 ounces for systems that are not equipped with rear A/C, and 58
ounces for vehicles that are equipped with rear A/C. Refer to Workshop Manual Section 412-00
A/C system leak diagnostics and system recovery, evacuation and recharging.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050411A 2004-2005 Expedition 0.6 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles Without Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
050411B 2004-2005 Expedition 0.8 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles With Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Customer Interest for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor Cooling Performance > Page
2728
DEALER CODING
CONDITION
BASIC PART NO. CODE
FREON 51
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor Cooling
Performance
Refrigerant: All Technical Service Bulletins A/C - Hooting/Whistling Noise/Poor Cooling
Performance
TSB 05-4-11
03/07/05
NOISE FROM A/C OR INSUFFICIENT A/C COOLING
FORD: 2004-2005 Expedition
LINCOLN: 2004-2005 Navigator
ISSUE Some 2004-2005 Expedition/Navigator vehicles built between 04/01/2004 and 9/26/2004,
may exhibit a hoot or whistle noise inside the passenger compartment, coming from the A/C
system. The vehicle may also exhibit insufficient A/C cooling. This may be due to low A/C
refrigerant charge from the factory.
ACTION If normal diagnostics do not point to a system leak, evacuate and recharge the A/C
system. Charge the system to 40 ounces for systems that are not equipped with rear A/C, and 58
ounces for vehicles that are equipped with rear A/C. Refer to Workshop Manual Section 412-00
A/C system leak diagnostics and system recovery, evacuation and recharging.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050411A 2004-2005 Expedition 0.6 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles Without Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
050411B 2004-2005 Expedition 0.8 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles With Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor Cooling
Performance > Page 2734
DEALER CODING
CONDITION
BASIC PART NO. CODE
FREON 51
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant Capacity
Without Auxiliary Climate Control ........................................................................................................
.........................................................40 oz (1.13 kg)
With Auxiliary Climate Control .............................................................................................................
.........................................................58 oz (1.64 kg)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 2737
Refrigerant: Fluid Type Specifications
Refrigerant Fluid ..................................................................................................................................
.......................................................................R-134a
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection
Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection
FLUORESCENT DYE LEAK DETECTION
Special Tool(s)
Special Tool(s)
Fluorescent Dye Detection
NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the
refrigerant system from the factory. The location of leaks can be pinpointed by the bright
yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist,
make sure to inspect each component, line, and fitting in the refrigerant system for a leak.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 2740
1. Check for leaks using a Rotunda approved UV lamp.
- Inspect all components, lines and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate
and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of
fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the
leak with a Rotunda-approved UV lamp.
Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
NOTE:
- Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the
desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is
not necessary to add dye after flushing or filtering the refrigerant system because a new suction
accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant
capacity has been lost due to a fitting separation, hose rupture or other damage.
- Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers
instructions on evacuation of any non-condensable gasses from the hoses.
- Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service
center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way
check valve that will prevent refrigerant system recovery and evacuation.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant
system service port valves.
2. Verify that the valves on the fluorescent dye injector are closed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 2741
3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the
fluorescent dye injector between the low-pressure service gauge port valve and the R-134a
refrigerant service center or manifold gauge
set.
5. Open all valves and inject the fluorescent dye into the refrigerant system. 6. When fluorescent
dye injection is complete, close all valves. 7. Recover the refrigerant from the R-134a fluorescent
dye injector. 8. Remove the fluorescent dye injector from the low-pressure service gauge port valve
and the R-134a A/C refrigerant service center or manifold
gauge set.
Fluorescent Dye Injection - Using a Dye Injector Loop Kit
NOTE:
- Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the
desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is
not necessary to add dye after flushing or filtering the refrigerant system because a new suction
accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant
capacity has been lost due to a fitting separation, hose rupture or other damage.
- Before using the R-134a fluorescent dye injector for the first time, refer to the equipment
manufacturers instructions on evacuation of non-condensable gasses from the hoses.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C.
1. Verify that the valves on the deluxe injector loop kit are closed.
2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye. 3. Install the
deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 2742
4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt
before starting the engine.
Start the engine.
5. Open the high-pressure service valve.
6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to
equalize with the suction side of the refrigerant
system.
8. NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating.
Close the valves on the deluxe injector loop kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 2743
9. NOTE: Leave all valves on the special tool closed when not in use.
Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop
kit from the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 2744
Refrigerant: Testing and Inspection Electronic Leak Detection
ELECTRONIC LEAK DETECTION
H10PM Refrigerant Leak Detector With Battery
Special Tool(s)
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate
this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner,
or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be
tested before proceeding with the leak detection procedure is helpful in removing small traces of
contamination from the air, but the fan should be turned off during actual testing.
1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, recover the refrigerant.
- Repair the system.
- Test the system for normal operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure
Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure
AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING
Special Tool(s)
Special Tool(s)
Refrigerant System Recovery
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that
may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to
leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify
that no leaks are present.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2747
1. Prior to recovering, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant
service center to the low- and high-pressure service gauge port valves following the operating
instructions provided
by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. 4. Once the refrigerant service center has recovered the refrigerant,
switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the
system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the
system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for two
minutes. 7. Carry out the required repairs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2748
Refrigerant: Service and Repair Evacuation and Charging
AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING
Special Tool(s)
Special Tool(s)
Refrigerant System Evacuation Using an R-134a Service Center
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that
may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to
leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify
that no leaks are present.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2749
1. Connect an R-134a service center to the low- and high-pressure service gauge port valves
following the operating instructions provided by the
equipment manufacturer.
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of
vacuum and as close to 101.1 kPa (30 in-Hg) as
possible. Continue to operate the vacuum pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low-pressure gauge for 5 minutes to make sure that the
system vacuum is held. If vacuum is not held for 5
minutes, leak test the system, repair the leak and evacuate the system again.
Refrigerant System Evacuation Using an R-134a Manifold Gauge Set
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that
may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to
leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify
that no leaks are present.
1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves.
2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum
pump. 3. Open all valves on the R-134a manifold gauge set and both service gauge port valves. 4.
Turn on the vacuum pump and evacuate the system until the low-pressure gauge reads at least
99.4 kPa (29.5 in-Hg) of vacuum and as close to
101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45
minutes.
5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port
valves) and turn off the vacuum pump. 6. Observe the low-pressure gauge for 5 minutes to make
sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the
system, repair the leak and evacuate the system again.
Refrigerant System Charging Using an R-134a Service Center
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be
misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Connect an R-134a
A/C service center to the low-side and high-side service gauge port valves following the operating
instructions provided by the
equipment manufacturer.
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions
provided by the equipment manufacturer.
Refrigerant System Charging
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be
misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Assemble the
R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following
the automatic refrigerant
charging meter operating instructions.
3. Charge the refrigerant system following the automatic refrigerant charging meter operating
instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the
engine, select A/C operation and allow the refrigerant charge to
complete.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2750
Refrigerant: Service and Repair Refrigerant Identification Testing
REFRIGERANT IDENTIFICATION TESTING
Refrigerant Identifier With Air-Radicator
Special Tool(s)
Refrigerant Identification
1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior
to recovering or charging the refrigerant system.
Follow the instructions included with the refrigerant identifier to obtain the sample for testing.
2. The diagnostic tool will display one of the following:
- If the purity level of R-134a is 98% or greater by weight, the green "PASS" light emitting diode
(LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be
displayed on the digital display.
- If refrigerant R-134a does not meet the 98% purity level, the red "FAIL" LED will light and an
alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12,
R-22, and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the
user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will
also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The diagnostic tool eliminates the effect of
air when determining the refrigerant sample content because air is not considered a contaminant,
although air can affect A/C system performance. When the diagnostic tool has determined that a
refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2%
or greater by weight, the diagnostic tool will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2751
Refrigerant: Service and Repair Contaminated Refrigerant Handling
CONTAMINATED REFRIGERANT HANDLING
CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the air
conditioning system flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
- If this equipment is not available, contact an A/C service facility in your area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern. 3. Flush the air conditioning
system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local
regulations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Refrigerant Oil Capacity
Without Auxiliary Climate Control ........................................................................................................
............................................................9 oz (266 ml)
With Auxiliary Climate Control .............................................................................................................
..........................................................14 oz (414 ml)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 2756
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil Type.............................................................................................................................
.......................................PAG Motorcraft YN-12-C
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2757
Refrigerant Oil: Service and Repair
REFRIGERANT OIL ADDING
Special Tool(s)
Special Tool(s)
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart for refrigerant oil adding amounts and methods of installation.
Refrigerant Oil Adding for New A/C Compressor Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2758
NOTE: Service A/C compressors are shipped without refrigerant oil.
1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the
refrigerant oil in a clean measuring cup.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), add
the same amount plus the amount collected during refrigerant recovery.
- If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 ounces), add
the same amount plus the amount collected during refrigerant recovery.
- If the amount of oil drained from the old A/C compressor is less than 85 ml (3 ounces), add 85 ml
(3 ounces) plus the amount collected during refrigerant recovery.
Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation
1. Drill one half-inch hole in the old suction accumulator or receiver/drier cylinder and drain the oil
into a clean measuring cup. 2. Add the quantity of oil drained, plus the amount collected during
refrigerant recovery and 60 ml (2 ounces).
Oil Injection Using a Dye/Lubricant Injector
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be
added to the dye/lubricant injector along with the refrigerant oil.
1. Evacuate the refrigerant system. 2. Assemble the dye/lubricant injector using the correct
adapters to match the amount of PAG oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean PAG oil. 5. Install the dye/lubricant
injector between the low-side service gauge port valve and the refrigerant service station or
manifold gauge set. 6. Open all valves and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer
Interest for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist
Brake Bleeding: Customer Interest Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist
Brake Bleeding: All Technical Service Bulletins Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 2772
Brake Bleeding: By Symptom
Technical Service Bulletin # 05-26-21 Date: 051231
Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 2773
Disclaimer
Technical Service Bulletin # 05-26-21 Date: 051231
Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > Page 2774
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2775
Brake Bleeding: Service and Repair
Brake System Bleeding
Special Tools And Equipment
Special Tool(s)
Material
Material
Master Cylinder, In Vehicle
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. 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 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2776
2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the
brake master cylinder reservoir with brake fluid. 3. Have an assistant pump the brake pedal until
clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and
install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows:
1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2.
Loosen the 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.
Four Wheel Anti-Lock Brake System (4WABS)
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: This procedure must be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control
unit (HCU) has been installed new.
NOTE: One conventional pressure bleed cycle consists of advancing the brake pedal to its
depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into
the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal.
NOTE: Performing the diagnostic program routine drives entrapped air from the otherwise
inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the
brakes). Subsequent 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 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2777
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 diagnostic tool.
Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash and follow the diagnostic tool instructions.
7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal
feels spongy, repeat the diagnostic tool service bleed procedure.
Gravity
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2778
with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic
system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When a new brake master cylinder has been installed or the system has been emptied, or
partially emptied, it should be primed to prevent air from getting into the system.
1. Fill the brake master cylinder reservoir with brake fluid.
2. Bleed the rear disc brake calipers.
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.
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2779
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.
Manual
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH rear disc brake caliper bleeder screw
and submerge the free end of the tube in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have
an assistant maintain pressure on the brake
pedal while tightening the RH rear disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2780
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.
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.
Pressure
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2781
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid
to complete the bleeding operation.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose
to the fitting on the adapter.
3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH rear disc brake caliper bleeder screw
and submerge the free end of the tube in a container partially filled with clean brake fluid.
4. Open the valve on the bleeder tank.
5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid
flows, then tighten rear disc brake caliper bleeder
screw and remove the rubber hose.
6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to
the RH front disc brake caliper ending with the LH
front disc brake caliper.
7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the
adapter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Page 2782
8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap.
Master Cylinder, Bench
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with
specified brake fluid.
^ Use clean brake fluid.
2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3.
Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles.
4. Remove the short brake tubes.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2787
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2788
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2789
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2790
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2791
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2792
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2793
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2794
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2795
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2796
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2797
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2798
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2799
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box
Fuse: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2805
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2806
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2807
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2808
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2809
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2810
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2811
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Central Junction Box > Page 2812
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box
Fuse: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2815
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2816
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2817
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2818
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2819
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2820
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2821
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Central Junction Box > Page 2822
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box
Fuse Block: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2827
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2828
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2829
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2830
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2831
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2832
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2833
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Central Junction Box > Page 2834
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views
Fuse Block: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2837
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2838
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2839
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2840
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2841
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2842
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box
Fuse Block: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2845
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2846
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2847
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2848
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2849
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2850
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2851
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Central Junction Box > Page 2852
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box
Relay Box: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2857
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2858
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2859
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2860
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2861
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2862
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2863
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Central Junction Box > Page 2864
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Page 2865
Relay Box: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Page 2866
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Page 2867
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Page 2868
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Page 2869
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Page 2870
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Page 2871
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Page 2872
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Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Page 2873
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box
Relay Box: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2876
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2877
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2878
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2879
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2880
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2881
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2882
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Central Junction Box > Page 2883
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Description and Operation
Low Tire Pressure Indicator: Description and Operation
TIRE PRESSURE MONITORING SYSTEM (TPMS)
When the Tire Pressure Monitoring System warning light is lit, one or more of your tires is
significantly under-inflated. You should stop and check your tires as soon as possible, and inflate
them to the proper pressure as indicated on the vehicle's tire information placard (label). Driving on
a significantly under-inflated tire causes the tire to overheat and can eventually lead to tire failure.
Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling
and stopping ability. Even if your vehicle is equipped with a Tire Pressure Monitoring System, it is
still Important that you manually check the inflation pressure of your tires regularly. Each tire,
including the spare, should be checked monthly when cold and set to the recommended inflation
pressure which can be found on either the tire label or certification label which is located on the
B-Pillar or the edge of the driver's door.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Description and Operation > Page 2888
Low Tire Pressure Indicator: Service and Repair
Sensor Training (Reset Procedure)
NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones and remote
transmitters, power inverters and portable entertainment equipment.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to
the RUN position three times, ending in the RUN position. Do not wait more than one minute
between each key cycle.
3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than one minute
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LF TIRE", place the magnet on the valve stem of the LF tire pressure sensor. The horn will
sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the VSM (TPMS module integral to VSM) does not recognize any one of the four tire
pressure sensors during the tire training procedure, the horn will sound twice and the message
center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be
repeated.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will display "TIRE TRAINING MODE COMPLETE".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
This vehicle is not equipped with a Maintenance Required Lamp/Indicator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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)
The MIL notifies the driver that the powertrain control module (PCM) has detected an OBD
emission-related component or system fault. When this occurs an OBD diagnostic trouble code
(DTC) will be set.
^ The MW is located in the instrument cluster and is labeled CHECK ENGINE SERVICE ENGINE
SOON or the ISO standard engine symbol.
^ The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
^ For applications with a dedicated hard wire MIL circuit the PCM will illuminate the MIL until a
profile ignition pickup (PIP) signal is detected. For 2OO5 the following vehicles use a hard wire
circuit: Crown Victoria/Grand Marquis Explorer Sport Trac and Ranger.
^ The MIL will remain illuminated after instrument cluster prove out if:
^ an emission related concern and DTC exists.
^ no PIP signal is detected (applications with a dedicated hard-wire MIL circuit). The PIP signal is
generated in the PCM using the crankshafi position (CKP) sensor. For these applications the MIL
can be helpful in diagnosing a no start.
^ the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
^ the PCM is operating in the Hardware Limited Operation Strategy (KLOS).
^ the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit).
^ The MIL remains off during the instrument cluster prove out if:
^ an indicator or instrument cluster concern is present.
^ the MIL circuit is open (applications with a dedicated hard wire MIL circuit).
^ To turn off the MIL afier a repair a reset command from the diagnostic tool must be sent or 3
consecutive drive cycles must be completed without a fault.
^ For all MIL concerns go to Symptom Charts.
^ If the MIL flashes at a steady rate a severe misfire condition may exist.
^ If the MIL flashes erratically the PCM can reset while cranking if the battery voltage is low.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
This vehicle is not equipped with a Oil Change Reminder Lamp.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING:
- The electrical power to the air suspension system must be shut down prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch located in the LH rear quarter trim panel area. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
- Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause
the vehicle to move.
- Support the vehicle prior to carrying out any procedure requiring the vehicle to be jacked off the
ground.
- Make sure the jack and jack stands are correctly located to prevent the vehicle from falling.
- Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack.
CAUTION:
- Never use a halfshaft as a lifting point.
- If equipped with retractable running board, disable the system through the instrument cluster
controls.
Jacking Points - Front
Jacking Points - Front
The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and
wheel assembly.
Jacking Points - Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 2902
Jacking Points - Rear
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Do not use the rear control arms as a lifting point.
The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire
and wheel assembly.
LIFTING
WARNING: The electrical power to the air suspension system must be shut down prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel area. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
CAUTION: Damage to suspension, exhaust and steering linkage components can occur if care is
not exercised when positioning the hoist adapters prior to lifting the vehicle.
Lifting Points - Twin Post Hoist
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 2903
Lifting Points - Twin Post Hoist
Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated.
Lifting Points - Drive On Hoist
Lifting Points - Drive On Hoist
The vehicle is supported by tires and suspension components.
Lifting Points - Floor Jack, Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 2904
Lifting Points - Floor Jack, Front
The front can be lifted using a floor jack under the front control arm directly below the shock.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Application and ID > Page 2909
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Page 2914
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Page 2915
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Page 2916
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Page 2917
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Description and Operation
Low Tire Pressure Indicator: Description and Operation
TIRE PRESSURE MONITORING SYSTEM (TPMS)
When the Tire Pressure Monitoring System warning light is lit, one or more of your tires is
significantly under-inflated. You should stop and check your tires as soon as possible, and inflate
them to the proper pressure as indicated on the vehicle's tire information placard (label). Driving on
a significantly under-inflated tire causes the tire to overheat and can eventually lead to tire failure.
Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling
and stopping ability. Even if your vehicle is equipped with a Tire Pressure Monitoring System, it is
still Important that you manually check the inflation pressure of your tires regularly. Each tire,
including the spare, should be checked monthly when cold and set to the recommended inflation
pressure which can be found on either the tire label or certification label which is located on the
B-Pillar or the edge of the driver's door.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Description and Operation > Page 2922
Low Tire Pressure Indicator: Service and Repair
Sensor Training (Reset Procedure)
NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones and remote
transmitters, power inverters and portable entertainment equipment.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to
the RUN position three times, ending in the RUN position. Do not wait more than one minute
between each key cycle.
3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than one minute
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LF TIRE", place the magnet on the valve stem of the LF tire pressure sensor. The horn will
sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the VSM (TPMS module integral to VSM) does not recognize any one of the four tire
pressure sensors during the tire training procedure, the horn will sound twice and the message
center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be
repeated.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will display "TIRE TRAINING MODE COMPLETE".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Application and ID > Page 2926
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Page 2930
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Page 2931
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Page 2932
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Page 2933
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 2942
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 2943
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 2944
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2950
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2951
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2952
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications
Wheel bearing-to-knuckle bolts
.............................................................................................................................................................
200 Nm (148 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications >
Page 2956
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp 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.
3. If the wheel (hub) is loose or does not rotate freely, install a new wheel hub.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position.
2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel and tire
assembly.
4. Remove the bolt and detach the retainers.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2959
6. Remove the brake disc.
7. Remove the dust cap.
8. Remove and discard the nut.
9. Remove the bolts and the wheel bearing and hub assembly.
10. CAUTION: If the original wheel bearing and hub is being reinstalled, make sure to install a new
O-ring.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2960
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating.
Remove and discard the rear axle wheel hub retainer and the washer
4. Using a suitable hub puller, separate the outboard CV joint from the wheel hub.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2961
6. Remove the brake disc.
7. Disconnect the wheel speed sensor electrical connector and detach the retainer.
8. Remove the bolt and detach the retainers.
9. Remove the bolts, the wheel bearing and the wheel speed sensor as an assembly.
^ Route the sensor wiring through the access hole in the brake shield.
^ Discard the bolts.
10. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Rear axle wheel hub retainer ...............................................................................................................
................................................... 345 Nm (254 lb. ft.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component
Information > Locations
Wheel Hub Lock Solenoid: Locations
INTEGRATED WHEEL ENDS SOLENOID
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component
Information > Locations > Page 2969
Wheel Hub Lock Solenoid: Diagrams
INTEGRATED WHEEL ENDS SOLENOID
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications >
Page 2973
Wheel Fastener: Service and Repair
Wheel Studs
Special Tool(s)
Special Tool(s)
Removal
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. Remove the wheel bearing.
2. CAUTION: Never use a hammer to remove a wheel stud. Damage to the wheel hub can result.
Place the wheel hub in a soft jawed vice and using the special tool remove the wheel stud
Installation
1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the flange can be
stripped.
NOTE: Do not use the wheel nut that came with the vehicle
Install the washers and wheel nut on the wheel stud and tighten the wheel nut until the stud seats
against the flange Discard the wheel nut
2. Install the wheel bearing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING:
- The electrical power to the air suspension system must be shut down prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch located in the LH rear quarter trim panel area. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
- Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause
the vehicle to move.
- Support the vehicle prior to carrying out any procedure requiring the vehicle to be jacked off the
ground.
- Make sure the jack and jack stands are correctly located to prevent the vehicle from falling.
- Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack.
CAUTION:
- Never use a halfshaft as a lifting point.
- If equipped with retractable running board, disable the system through the instrument cluster
controls.
Jacking Points - Front
Jacking Points - Front
The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and
wheel assembly.
Jacking Points - Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
2977
Jacking Points - Rear
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Do not use the rear control arms as a lifting point.
The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire
and wheel assembly.
LIFTING
WARNING: The electrical power to the air suspension system must be shut down prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel area. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
CAUTION: Damage to suspension, exhaust and steering linkage components can occur if care is
not exercised when positioning the hoist adapters prior to lifting the vehicle.
Lifting Points - Twin Post Hoist
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
2978
Lifting Points - Twin Post Hoist
Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated.
Lifting Points - Drive On Hoist
Lifting Points - Drive On Hoist
The vehicle is supported by tires and suspension components.
Lifting Points - Floor Jack, Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
2979
Lifting Points - Floor Jack, Front
The front can be lifted using a floor jack under the front control arm directly below the shock.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2991
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2992
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 2993
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 2998
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up
Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3004
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3005
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3006
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3011
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3014
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 3015
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAM TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At
idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air
flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the
PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems
provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS
systems also have the added benefit of improved torque. In addition, some VCT system
applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The
elimination of the EGR system is accomplished by controlling the overlap time between the intake
valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used.
Variable Cam Timing (VCT) System
Variable Cam Timing System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments.
1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant
temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system will not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It will continually update the
VCT solenoid duty cycle until the desired position is achieved. A difference between the desired
and actual camshaft position represents a position error in the PCM VCT control loop. The PCM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 3016
will disable the VCT and place the camshaft in a default position if a fault is detected. A related
DTC will also be set when the fault is detected.
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the cam timing. One
half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing
chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow
of oil is shifted from one side of the chamber to the other, the differential change in oil pressure
forces the camshaft to rotate in either a advance or retard position depending on the oil flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Service and Repair
Variable Valve Timing Solenoid: Service and Repair
VARIABLE CAMSHAFT TIMING OIL CONTROL SOLENOID
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the variable camshaft timing (VCT) oil
control solenoid electrical connector. 3. Remove the VCT oil control solenoid grommet. 4. Remove
the bolt and the VCT oil control solenoid. Discard the O-ring seal.
- To install, tighten to 5 Nm (44 lb-in).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
GENERAL SPECIFICATIONS
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 3023
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 3024
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications
Camshaft Bearing: Specifications
TORQUE SPECIFICATIONS
Camshaft Bearing ................................................................................................................................
................................................. 10 Nm (89 inch lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
TORQUE SPECIFICATIONS
LH and RH Camshaft Phaser Sprocket Bolts
Stage 1 ................................................................................................................................................
.................................................. 40 Nm (30 ft. lbs.) Stage 2 ................................................................
............................................................................................................................. additional 90
degrees.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications > Page 3032
Camshaft Gear/Sprocket: Service and Repair
Special Tool(s)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional
information, refer to Camshaft - RH. See:
Camshaft/Service and Repair
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional
information, refer to Camshaft - LH. See:
Camshaft/Service and Repair
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
- If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
- If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications > Page 3033
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Installation
1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to
valves and pistons will result.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional
information, refer to Camshaft - RH. See:
Camshaft/Service and Repair
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional
information, refer to Camshaft - LH. See:
Camshaft/Service and Repair
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures
Camshaft: Service and Repair General Procedures
Camshaft Journal-Diameter
1. Measure each camshaft journal diameter in two directions.
^ If out of specification, install new components as necessary.
Camshaft Journal-Clearance, Plastigage Method
Special Tools And Equipment
Special Tool(s)
NOTE: The camshaft journals must meet specifications before checking camshaft journal
clearance.
1. Remove the camshaft bearing cap and lay Plastigage across the surface.
2. NOTE: Do not turn the camshaft while carrying out this procedure.
Position the camshaft bearing cap and install the bolts.
3. Use Plastigage to verify the camshaft journal clearance.
^ If out of specification, install new components as necessary.
Camshaft End Play
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3038
Special Tools And Equipment
Special Tool(s)
1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play. 2. Position the
camshaft to the rear of the cylinder head. 3. Zero the indicator.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.
^ If camshaft end play exceeds specifications, install new camshaft and recheck end play.
^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.
Camshaft-Lobe Surface
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable
outside the contact area.
^ If excessive pitting or damage is present, install new components as necessary.
Camshaft Lobe Lift
Special Tools And Equipment
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3039
1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake exhaust lobe lift.
^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading
to figure the camshaft lobe lift.
^
Camshaft Runout
Special Tools And Equipment
Special Tool(s)
1. NOTE: Camshaft journals must be within specifications before checking runout.
Use a Dial Indicator Gauge with Holding Fixture to measure the camshaft runout. ^
Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading.
^ For additional information, refer to the specification chart in the appropriate engine section.
^ If out of specification, install new components as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3040
Camshaft: Service and Repair Camshaft - LH
Special Tool(s)
Material
Removal
NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons
will result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
2. Remove the LH valve cover.
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3041
4. Disconnect the LH camshaft position (CMP) sensor electrical connector.
5. Remove the LH CMP sensor and the bolt.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will
require one full additional rotation to 12 o'clock.
The No.5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the
position of the 2 intake camshaft lobes and the exhaust lobe on the No.5 cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3042
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTICE: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure to follow
these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove only the 3 designated camshaft roller followers from the previous
step.
9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3043
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke
at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage
to valves and pistons will result.
NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine
block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the LH timing chain as shown.
11. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
NOTE: RH shown, LH similar.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3044
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from side
loading.
Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.
Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft
bearing caps.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3045
14. Clean and inspect the LH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly,
leaving the camshaft phaser and sprocket assembly in place.
Discard the bolt and washer.
16. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to
Camshaft Phaser and Sprocket. See: In-Vehicle Repair
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3046
Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a
new camshaft phaser and sprocket bolt finger-tight.
3. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
NOTE: RH shown, LH similar.
Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3047
5. Tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity.
Remove the special tools.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3048
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at
the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No.5 cylinder intake and exhaust
camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed. For additional information, refer to Cylinder Head. See: Cylinder
Head Assembly
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3049
11. Connect the CMP electrical connector.
12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage
may occur to the camshaft or camshaft phaser and
sprocket.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Tighten the camshaft phaser and sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90°.
13. In stall the LH valve cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3050
Camshaft: Service and Repair Camshaft - RH
Special Tool(s)
Material
Removal
NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons
will result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
2. Remove the RH valve cover.
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Loosen and back off the RH camshaft phaser and sprocket bolt one full turn.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3051
4. Disconnect the RH camshaft position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one
full additional rotation to 12 o'clock.
The No.1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by
noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No.1 cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3052
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTICE: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure to follow
these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove only the 3 designated camshaft roller followers from the previous
step.
9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke
at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3053
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage
to valves and pistons will result.
NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine
block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the RH timing chain as shown.
11. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from side
loading.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3054
Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.
Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft
bearing caps.
14. Clean and inspect the RH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3055
Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly,
leaving the camshaft phaser and sprocket assembly in place. Discard the bolt and washer.
16. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to
Camshaft Phaser and Sprocket. See: Camshaft
Gear/Sprocket
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a
new camshaft phaser and sprocket bolt finger-tight.
3. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3056
Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
5. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3057
Remove the special tool.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at
the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No.1 cylinder intake and exhaust
camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3058
Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
11. Connect the CMP electrical connector.
12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage
may occur to the camshaft or camshaft phaser and
sprocket.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Tighten the new camshaft phaser and sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3059
- stage 2: Tighten an additional 90°.
13. Install the RH valve cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3060
Camshaft: Service and Repair In-Vehicle Repair
Special Tool(s)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional
information, refer to Camshaft - RH. See:
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional
information, refer to Camshaft - LH. See:
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
- If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
- If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3061
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Installation
1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to
valves and pistons will result.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional
information, refer to Camshaft - RH. See:
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional
information, refer to Camshaft - LH. See:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3062
Camshaft: Service and Repair Variable Camshaft Timing (VCT) Solenoid
Removal and Installation All vehicles
1. Disconnect the battery ground cable. See: Starting and Charging/Battery/Battery Cable
Early build vehicles
2. Remove the power steering reservoir and support bracket lower bolt. To install, tighten to 25 Nm
(18 lb-ft).
3. Remove the nut and position the power steering reservoir and support bracket aside. To install,
tighten to 25 Nm (18 lb-ft).
All vehicles
4. Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector. 5.
Remove the VCT oil control solenoid grommet.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 3063
6. Remove the bolt and the VCT oil control solenoid. To install, tighten to 5 Nm (44 lb-in). 7. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Lifter / Lash Adjuster: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3072
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3073
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3074
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Lifter / Lash Adjuster: Customer Interest Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: >
05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3079
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3085
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3086
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3087
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3092
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > General Procedures
Lifter / Lash Adjuster: Service and Repair General Procedures
Hydraulic Lash Adjuster-Inspection
1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found,
inspect the camshaft lobes and valves for damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > General Procedures > Page 3095
Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjuster
Hydraulic Lash Adjuster
Material
Material
Removal and Installation
1. Remove the camshafts. 2. Remove the remaining roller followers from the cylinder head being
serviced.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Remove the hydraulic lash adjusters that are being serviced.
4. Inspect the hydraulic lash adjusters.
5. NOTE: Lubricate each of the hydraulic lash adjusters with clean engine oil prior to installation.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Camshaft Roller Follower
Rocker Arm Assembly: Service and Repair Camshaft Roller Follower
Camshaft Roller Follower
Special Tools And Equipment
Special Tool(s)
Material
Material
Removal
1. Depending on the roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the
crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve
and the exhaust valves closed.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same position.
Mark the components for installation into the
original location.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Camshaft Roller Follower > Page 3100
1. CAUTION: If the components are to be reinstalled, they must be installed in the same position.
Mark the components for installation into the
original locations.
Using the special tool, compress the valve spring and install the camshaft roller follower.
2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve
being serviced, install the LH or RH valve cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Camshaft Roller Follower > Page 3101
Rocker Arm Assembly: Service and Repair General Procedures
Roller Follower-Inspection
1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft
lobes and hydraulic lash adjuster for damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3110
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3111
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3112
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing
Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3117
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up
Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3123
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3124
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3125
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve
Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3130
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3133
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 3134
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAM TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At
idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air
flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the
PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems
provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS
systems also have the added benefit of improved torque. In addition, some VCT system
applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The
elimination of the EGR system is accomplished by controlling the overlap time between the intake
valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used.
Variable Cam Timing (VCT) System
Variable Cam Timing System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments.
1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant
temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system will not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It will continually update the
VCT solenoid duty cycle until the desired position is achieved. A difference between the desired
and actual camshaft position represents a position error in the PCM VCT control loop. The PCM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 3135
will disable the VCT and place the camshaft in a default position if a fault is detected. A related
DTC will also be set when the fault is detected.
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the cam timing. One
half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing
chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow
of oil is shifted from one side of the chamber to the other, the differential change in oil pressure
forces the camshaft to rotate in either a advance or retard position depending on the oil flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
GENERAL SPECIFICATIONS
Connecting Rod
Connecting rod-to-pin clearance
............................................................................................................................. 0.009-0.0235 mm
(0.0004-0.0093 in) Connecting rod pin bore diameter
......................................................................................................................... 22.012-22.024 mm
(0.8666-0.8671 in) Connecting rod length (center-to-center)
......................................................................................................................................... 169.1 mm
(6.6575 in) Connecting rod maximum allowed bend
....................................................................................................................................... ± 0.038 mm
(0.0015 in) Connecting rod maximum allowed twist (see footnote b)
............................................................................................................... ± 0.05 mm (0.0020 in)
Connecting rod bearing bore diameter (with assembled liners)
............................................................................. 53.049-53.027 mm(2.0885-2.0877 in) Connecting
rod bearing-to-crankshaft clearance
....................................................................................................... 0.064-0.026 mm (0.0025-0.0010
in) Connecting rod side clearance
.................................................................................................................................. 0.475-0.125 mm
(0.0187-0.0049 in)
Footnotes:
a The time for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down
fluid in the lash adjuster.
b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the
specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of
rod centerline.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > General Specifications
Connecting Rod: Specifications General Specifications
GENERAL SPECIFICATIONS
Connecting Rod
Connecting rod-to-pin clearance
............................................................................................................................. 0.009-0.0235 mm
(0.0004-0.0093 in) Connecting rod pin bore diameter
......................................................................................................................... 22.012-22.024 mm
(0.8666-0.8671 in) Connecting rod length (center-to-center)
......................................................................................................................................... 169.1 mm
(6.6575 in) Connecting rod maximum allowed bend
....................................................................................................................................... ± 0.038 mm
(0.0015 in) Connecting rod maximum allowed twist (see footnote b)
............................................................................................................... ± 0.05 mm (0.0020 in)
Connecting rod bearing bore diameter (with assembled liners)
............................................................................. 53.049-53.027 mm(2.0885-2.0877 in) Connecting
rod bearing-to-crankshaft clearance
....................................................................................................... 0.064-0.026 mm (0.0025-0.0010
in) Connecting rod side clearance
.................................................................................................................................. 0.475-0.125 mm
(0.0187-0.0049 in)
Footnotes:
a The time for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down
fluid in the lash adjuster.
b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the
specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of
rod centerline.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > General Specifications > Page 3144
Connecting Rod: Specifications Torque Specifications
TORQUE SPECIFICATIONS
Connecting Rod Bolts
Stage 1 ................................................................................................................................................
.................................................. 43 Nm (32 ft. lbs.) Stage 2 ................................................................
........................................................................................................................... additional 105
degrees.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 3145
Connecting Rod: Service and Repair
Connecting Rod-Cleaning
CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed
on the original connecting rod in the original
position. Do not reverse the cap. Parts are not interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
Connecting Rod-Large End Bore
1. Tighten the bolts to specification, then measure the bore in two directions. The difference is the
connecting rod bore out-of-round. Verify the
out-of-round is within specification.
^ If out of specification, install new components as necessary.
Connecting Rod-Bushing Diameter
1. Measure the inner diameter of the connecting rod bushing, if equipped. Verify the diameter is
within specification.
^ If out of specification, install new components as necessary.
Connecting Rod-Bend
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 3146
1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the bend measurement
is within specification.
^ If out of specification, install new components as necessary.
Connecting Rod-Twist
1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the measurement is
within specification.
^ If out of specification, install new components as necessary.
Connecting Rod-Piston Pin Side Clearance
1. Measure the clearance between the connecting rod and the piston. Verify the measurement is
within specification.
^ If out of specification, install new components as necessary.
Connecting Rod-Bearing Journal Clearance
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 3147
Special Tools And Equipment
Special Tool(s)
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing.
^ If out of specification, install new components as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > General Specifications
Crankshaft Main Bearing: Specifications General Specifications
GENERAL SPECIFICATIONS
Main bearing
Main bearing journal diameter
............................................................................................................................... 67.481-67.505
mm(2.6567-2.6576 in) Main bearing journal maximum taper
.............................................................................................................................................. 0.004
mm (0.0002 in) Main bearing journal maximum out-of-round
............................................................................................ 0.0075 mm (0.0003 in)between cross
sections Main bearing journal-to-cylinder block clearance
.................................................................................................... 0.048-0.024 mm(0.0019-0.0009 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > General Specifications > Page 3152
Crankshaft Main Bearing: Specifications Torque Specifications
TORQUE SPECIFICATIONS
MAIN BEARINGS
Vertical Main Bearing Cap
Stage 1 ................................................................................................................................................
.................................................. 40 Nm (30 ft. lbs.) Stage 2 ................................................................
.............................................................................................................................. additional 90
degrees
Side Bolts
Stage 1 ................................................................................................................................................
.................................................. 30 Nm (22 ft. lbs.) Stage 2 ................................................................
............................................................................................................................. additional 90
degrees.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 3153
Crankshaft Main Bearing: Service and Repair
Bearing-Inspection
1. Inspect bearings for the following defects.
Possible causes are shown: 1. Cratering-fatigue failure. 2. Spot polishing-incorrect seating. 3.
Imbedded dirt engine oil. 4. Scratching-dirty engine oil. 5. Base exposed-poor lubrication. 6. Both
edges worn-journal damaged. 7. One edge worn-journal tapered or bearing not seated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
GENERAL SPECIFICATIONS
Crankshaft
Main bearing journal diameter
............................................................................................................................... 67.481-67.505
mm(2.6567-2.6576 in) Main bearing journal maximum taper
.............................................................................................................................................. 0.004
mm (0.0002 in) Main bearing journal maximum out-of-round
............................................................................................ 0.0075 mm (0.0003 in)between cross
sections Main bearing journal-to-cylinder block clearance
.................................................................................................... 0.048-0.024 mm(0.0019-0.0009 in)
Connecting rod journal diameter
............................................................................................................................ 53.003-52.983
mm(2.0867-2.0859 in) Connecting rod journal maximum taper
.......................................................................................................................................... 0.004 mm
(0.0002 in) Connecting rod journal maximum out-of-round
........................................................................................ 0.0075 mm (0.0003 in)between cross
sections Crankshaft maximum end play
................................................................................................................................... 0.075-0.377
mm(0.0030-0.0148 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 3157
Crankshaft: Service and Repair
Crankshaft Main Bearing Journal- Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least two directions.
^^
If out of specification, install new components as necessary.
Crankshaft Main Bearing Journal- Taper
1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each
end of the main bearing journal.
^^
If out of specification, install new components as necessary.
Crankshaft Main Bearing Journal- Clearance
Special Tools And Equipment
Special Tool(s)
NOTE: Crankshaft main bearing journals must be within specifications before checking journal
clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 3158
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.
^^
If out of specification, install new components as necessary.
Crankshaft End Play
Special Tools And Equipment
Special Tool(s)
1. Measure the crankshaft end play. Use a Dial Indicator Gauge with Holding Fixture to measure
crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the
indicator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 3159
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft
thrust main bearing.
Crankshaft Runout
Special Tools And Equipment
Special Tool(s)
1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout.
Use the Dial Indicator Gauge with Holding Fixture to measure the crankshaft runout. ^ ^
Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator
reading to figure the crankshaft runout. If it is out of specification, install new components as
necessary.
Crankshaft-Connecting Rod Journal Taper, Out of Round
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 3160
1. Measure the crankshaft connecting rod journal diameters in two directions perpendicular to one
another at each end of the connecting rod journal.
The difference in the measurements from one end to the other is the taper. Verify measurement is
within the wear limit. ^ ^
If out of specification, install new components as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair
Engine Block Heater: Service and Repair
Block Heater
Material
Material
Removal and Installation
1. Drain the engine cooling system.
2. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal.
Loosen the block heater retaining screw and remove the block heater. ^
To install, tighten to 2 Nm (18 inch lbs.).
3. NOTE: Route the block heater power cable away from hot or rotating components, or damage to
the cable can occur.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair
Expansion/Freeze Plug: Service and Repair
Cylinder Block Core Plug Replacement
Special Tools And Equipment
Special Tool(s)
Material
Material
1. Use a slide hammer or tools suitable to remove the cylinder block core plug. 2. Inspect the
cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. If
the cylinder block plug bore is
damaged, bore for the next oversize plug.
3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the
plug.
Coat the cylinder block core plug and bore lightly with High Strength Thread-locker and install the
cylinder block core plug.
Cup-Type
1. CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair > Page 3167
CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to
effectively seal the bore.
Use a tool suitable to seat the cup-type cylinder block core plug.
Expansion-Type
1. CAUTION: Do not contact the crown when installing an expansion-type cylinder block core plug.
This could expand the plug before seating and
result in leakage.
Use tool suitable to seat the expansion-type cylinder block core plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
TORQUE SPECIFICATIONS
Crankshaft Pulley Bolt
Stage 1 ................................................................................................................................................
.................................................. 90 Nm (66 ft. lbs.) Stage 2 ................................................................
............................................................................................................................... Loosen 360
degrees. Stage 3 .................................................................................................................................
................................................................. 50 Nm (37 ft. lbs.) Stage 4 .................................................
............................................................................................................................................ additional
90 degrees.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3171
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Pulley
Special Tools And Equipment
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3172
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the engine cooling fan lower
shroud.
3. Rotate the tensioner clockwise and remove the accessory drive belt. 4. Remove the crankshaft
pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.
Installation
1. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area
cleaned with metal surface prep and silicone gasket
remover. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure
to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3173
2. Using the special tool, install the crankshaft pulley.
3. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
4. Rotate the tensioner clockwise and install the accessory drive belt. 5. Install the engine cooling
fan lower shroud.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
GENERAL SPECIFICATIONS
Piston
Piston diameter - grade 1 (at right angle to pin bore)
............................................................................................ 90.175-90.165 mm (3.5502-3.5498 in)
Piston diameter - grade 2 (at right angle to pin bore)
............................................................................................ 90.185-90.175 mm (3.5506-3.5502 in)
Piston diameter - grade 3 (at right angle to pin bore)
............................................................................................ 90.195-90.185 mm (3.5510-3.5506 in)
Piston-to- cylinder bore clearance (at grade size)
..................................................................................................... 0.025-0.045 mm (0.0010-0.0018
in) Piston pin bore diameter
.......................................................................................................................................
22.008-22.014 mm (0.8665-0.8667 in) Piston pin diameter
...........................................................................................................................................
22.0010-22.0030 mm (0.8662-0.8663 in) Piston pin length ................................................................
.................................................................................................................. 61.8 mm (2.433 in) Piston
pin-to-piston fit
..............................................................................................................................................
0.005-0.013 mm (0.0002-0.0005 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures
Piston: Service and Repair General Procedures
Piston Inspection
Special Tools And Equipment
Special Tool(s)
CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage
can occur.
1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If
wear marks, scores or glazing is found on the piston
skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves.
^ Make sure the oil ring holes are clean.
Piston-Pin to Bore Diameter
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures > Page 3179
1. WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer
ring, since it has a tendency to spring
out. Wear eye protection.
NOTE: Piston and piston pins are a matched set and should not be interchanged.
Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within
specification. ^
If out of specification, install new components as necessary.
Piston-Diameter
1. Measure the piston diameter 90 degrees from the piston pin and 42 mm down from the top of the
piston at the point indicated.
^ If out of specification, install new components as necessary.
Piston-to Cylinder Bore Clearance
Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Piston-Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting
a piston.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures > Page 3180
1. Select a piston size based on the cylinder bore.
2. NOTE: For precision fit, new pistons are divided into three categories within each size range
based on their relative position within the range. A
paint spot on the new pistons indicates the position within the size range.
Choose the piston with the correct paint color. ^
Piston-Ring End Gap
CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
CAUTION: Piston rings should not be transferred from one piston to another.
NOTE: Cylinder bore must be within specification for taper and out-of-round.
1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures > Page 3181
2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap.
^
Piston-Ring-to-Groove Clearance
1. Inspect the piston for ring land damage or accelerated wear.
2. Measure the piston ring-to-groove clearance.
^^
If out of specification, install new components as necessary.
Piston-Pin Diameter
1. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is
within specification.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures > Page 3182
^^
If out of specification, install new components as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures > Page 3183
Piston: Service and Repair Disassembly and Assembly
Piston
Material
Material
Disassembly
1. Remove the piston rings from the piston.
^ Discard the piston rings.
2. Remove the piston pin retainers and the piston pin. 3. Separate the piston from the connecting
rod. 4. Clean and inspect the piston and connecting rod.
Assembly
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > General Procedures > Page 3184
1. NOTE: The connecting rod must be installed into the piston with identification markings toward
the front.
Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil. 3. Install the piston pin in the piston
and connecting rod assembly. 4. Install the piston pin retaining clips in the piston. 5. Lubricate the
piston and the new piston rings with clean engine oil. 6. Install the piston rings onto the piston.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
GENERAL SPECIFICATIONS
Piston ring
Piston ring end gap - top
...................................................................................................................................................
0.15-0.30 mm (0.006-0.012 in) Piston ring end gap - intermediate
................................................................................................................................ 0.25-0.50 mm
(0.0098-0.0197 in) Piston ring end gap - oil control
.................................................................................................................................... 0.15-0.65 mm
(0.0059-0.0256 in) Piston ring groove width - top
....................................................................................................................................... 1.52-1.55
mm (0.0598-0.0610 in) Piston ring groove width- intermediate
......................................................................................................................... 1.52-1.54 mm
(0.0598-0.0606 in) Piston ring groove width - oil control
....................................................................................................................... 3.030-3.050 mm
(0.1193-0.1201 in) Piston ring width - top and intermediate
....................................................................................................................... 1.50-1.47 mm
(0.0590-0.0578 in) Piston ring-to-groove clearance - top
........................................................................................................................ 0.020-0.080 mm
(0.0008-0.0031 in) Piston ring-to-groove clearance - intermediate
......................................................................................................... 0.030-0.070 mm (0.0012-0.0028
in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
GENERAL SPECIFICATIONS
Valves
Valve stem-to-guide clearance - intake
.......................................................................................................................... 0.020-0.045
mm(0.001-0.002 in) Valve stem-to-guide clearance - exhaust
........................................................................................................................ 0.069-0.094
mm(0.003-0.004 in) Valve head diameter intake
............................................................................................................................................
33.62-33.98 mm(1.324-1.338 in) Valve head diameter exhaust
................................................................................................................................... 37.32-37.68
mm(1.469-1.483 in) Valve face runout ................................................................................................
................................................................................ 0.05 mm (0.002 in) Valve face angle ..................
..............................................................................................................................................................
............. 45.5 degrees Valve seat width intake
..........................................................................................................................................................
1.2-1.4 mm (0.047-0.055in) Valve seat width exhaust
........................................................................................................................................................
1.4-1.6 mm (0.055-0.063in) Valve seat angle .....................................................................................
................................................................................................ 44.5-45.0 degrees Valve spring free
length ...................................................................................................................................................
..................... 55.7 mm (2.19 in) Valve spring compression pressure
................................................................................................. 350 N (79 lbs) ± 17.5 N(4 lbs) (a
42.04 mm (1.66in) Valve spring installed height ..................................................................................
............................................................................. 42.04 mm (1.66 in) Valve spring installed
pressure ..................................................................................................... 350 N (79 lbs) ± 17.5 N
(4 lbs) @ 42.04 mm (1.66 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Camshaft Roller Follower
Rocker Arm Assembly: Service and Repair Camshaft Roller Follower
Camshaft Roller Follower
Special Tools And Equipment
Special Tool(s)
Material
Material
Removal
1. Depending on the roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the
crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve
and the exhaust valves closed.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same position.
Mark the components for installation into the
original location.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Camshaft Roller Follower > Page 3199
1. CAUTION: If the components are to be reinstalled, they must be installed in the same position.
Mark the components for installation into the
original locations.
Using the special tool, compress the valve spring and install the camshaft roller follower.
2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve
being serviced, install the LH or RH valve cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Camshaft Roller Follower > Page 3200
Rocker Arm Assembly: Service and Repair General Procedures
Roller Follower-Inspection
1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft
lobes and hydraulic lash adjuster for damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Valve Cover-LH
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3205
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3206
Removal
1. Remove the air cleaner intake pipe. 2. Remove the LH ignition coils. 3. Remove the nut, the bolt
and position the power steering reservoir and support bracket aside. 4. Remove the positive
crankcase ventilation (PCV) tube. 5. Remove the bolt and position the oil level indicator tube aside.
6. Disconnect the radio ignition interference capacitor electrical connector. 7. Disconnect the
variable camshaft timing (VCT) solenoid electrical connector and the wiring harness retainers. 8.
Disconnect the intake manifold vacuum tube hose from the brake booster. 9. Remove the nut and
position the intake manifold vacuum tube assembly aside.
10. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Loosen the 15 fasteners and remove the LH valve cover and gasket. ^
Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3207
^ Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a
suitable solvent.
Installation
1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner.
Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the
cylinder head.
2. Position the LH valve cover and new gasket on the cylinder head and tighten the bolts in the
sequence shown
^ Tighten to 10 Nm (89 inch lbs.).
3. Position the intake manifold vacuum tube assembly and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
4. Connect the intake manifold vacuum tube hose to the brake booster. 5. Connect the VCT
solenoid electrical connector and the wiring harness retainers. 6. Connect the radio ignition
interference capacitor electrical connector. 7. Position the oil level indicator tube and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
8. Install the PCV tube. 9. Position the power steering reservoir and support bracket and install the
nut.
^ Tighten to 10 Nm (89 inch lbs.).
10. Install the power steering reservoir and support bracket lower bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
11. Install the LH ignition coils. 12. Install the air cleaner intake pipe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3208
Valve Cover: Service and Repair RH
Valve Cover-RH
Special Tools And Equipment
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3209
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3210
Removal
1. Recover the refrigerant. 2. Remove the powertrain control module (PCM) and support bracket. 3.
Remove the RH variable camshaft timing (VCT) oil control solenoid. 4. Remove the RH ignition
coils. 5. Remove the crankcase vent tube. 6. Disconnect the wiring harness retainers from the
valve cover.
7. Disconnect the A/C tube spring lock couplings.
^ Discard the O-ring seals.
8. Remove the bolt and position the A/C tube aside.
^ Discard the O-ring seal.
9. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Loosen the 15 fasteners and remove the RH valve cover and gasket. ^
Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
^ Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a
suitable solvent.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3211
1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner.
Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the
cylinder head.
2. Position the LH valve cover and new gasket on the cylinder head and tighten the bolts in the
sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
3. Using new O-ring seals, connect the A/C tube spring lock couplings.
^ Discard the O-ring seals.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3212
4. Using a new O-ring seal, position the A/C tube and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
5. Connect the wiring harness retainers to the valve cover. 6. Install the crankcase vent tube. 7.
Install the RH ignition coils. 8. Install the PCM and support bracket. 9. Install the RH VCT oil control
solenoid.
10. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Service and Repair
Valve Guide: Service and Repair
Valve-Stem to Valve Guide Clearance
Special Tools And Equipment
Special Tool(s)
NOTE: Valve stem diameter must be within specifications before checking valve stem to valve
guide clearance.
1. NOTE: If necessary, use a magnetic base.
Install a Valve Stem Clearance Tool on the valve stem and install a Dial Indicator with Bracketry.
Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide.
2. Move the Valve Stem Clearance Tool toward the indicator and zero the indicator. Move the
Valve Stem Clearance Tool away from the indicator
and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.
Valves with oversize stems will need to be installed if out of specification.
Valve-Guide Inner Diameter
1. Measure the inner diameter of the valve guides in two directions where indicated.
2. If the valve guide is not within specifications, ream the valve guide and install a valve with an
oversize stem or remove the valve guide and install
a new valve guide.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Service and Repair > Page 3216
Valve-Guide Reaming
1. Use a hand-reaming kit to ream the valve guide. 2. Reface the valve seat. 3. Clean the sharp
edges left by reaming.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair
Valve Seat: Service and Repair
Valve-Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the
diameter is within specification.
^ If out of specification, install new components as necessary.
Valve-Inspection
1. Inspect the following valve areas:
1. the end of the stem for grooves or scoring 2. the valve face and the edge for pits, grooves or
scores 3. the valve head for signs of burning, erosion, warpage and cracking 4. the valve margin
for wear
Valve-Seat Inspection
Valve and Seat Refacing Measurements
CAUTION: After grinding valves or valve seats, check valve clearance.
1. Check the valve head and seat.
^ Check valve angles.
^ Check margin width.
^ Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Page 3220
Valve-Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
^ Measure the intake valve seat width.
^ Measure the exhaust valve seat width.
^ Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
^
Valve-Seat Runout
1. Use the Valve Seat Runout Gauge to check valve seat runout.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > General Procedures
Valve Spring: Service and Repair General Procedures
Valve-Spring Installed Length
1. Measure the installed length of each valve spring.
^ If out of specification, install new components.
Valve-Spring Free Length
1. Measure the free length of each valve spring.
^ If out of specification, install new components as necessary.
Valve-Spring Squareness
1. NOTE: This procedure only applies to cylindrical valve springs.
Measure the out-of-square on each valve spring. ^
Turn the valve spring and observe the space between the top of the valve spring and the square.
Install a new valve spring if out of square.
Valve Spring Strength
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > General Procedures > Page 3225
Special Tools And Equipment
Special Tool(s)
1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
^ If out of specification, install new components as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > General Procedures > Page 3226
Valve Spring: Service and Repair Valve Springs
Valve Springs
Special Tools And Equipment
Special Tool(s)
Removal
1. Depending on the valve being serviced, remove the LH or RH valve cover. 2. Remove the spark
plug. 3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke
with the intake valve and the exhaust valves closed.
4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position.
^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder.
If air pressure must be removed, support the valve prior to removal.
CAUTION: If the components are to be reinstalled, they must be installed in the same position.
Mark the components for location.
NOTE: If a valve drops into the cylinder, remove the cylinder head.
Using the special tool, compress the valve spring and remove the valve spring retainer keys.
7. Remove the valve spring retainer and the valve spring. 8. Inspect the valve spring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > General Procedures > Page 3227
Installation
1. Using the special tool, install the valve spring, the valve spring retainer and the valve spring
retainer keys.
2. Relieve the air pressure from the cylinder.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Using the special tool, compress the valve spring and install the camshaft roller follower.
4. Install the spark plug. 5. Depending on the valve being serviced, install the LH or RH valve
cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair
Valve: Service and Repair
Valve-Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the
diameter is within specification.
^ If out of specification, install new components as necessary.
Valve-Inspection
1. Inspect the following valve areas:
1. the end of the stem for grooves or scoring 2. the valve face and the edge for pits, grooves or
scores 3. the valve head for signs of burning, erosion, warpage and cracking 4. the valve margin
for wear
Valve-Seat Inspection
Valve and Seat Refacing Measurements
CAUTION: After grinding valves or valve seats, check valve clearance.
1. Check the valve head and seat.
^ Check valve angles.
^ Check margin width.
^ Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Page 3231
Valve-Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
^ Measure the intake valve seat width.
^ Measure the exhaust valve seat width.
^ Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
^
Valve-Seat Runout
1. Use the Valve Seat Runout Gauge to check valve seat runout.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Locations
Drive Belt: Locations
Accessory Drive
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Locations > Page 3236
Drive Belt: Diagrams
Accessory Drive
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Locations > Page 3237
Drive Belt: Description and Operation
Accessory Drive
The accessory drive system:
- has a single serpentine drive belt (6 ribs). - has 3 idler pulleys. - has an automatic belt tensioner. is not adjustable.
The accessory drive system provides power to operate components which power other systems.
These could include components such as the generator, power steering pump, and A/C
compressor. Each of these components is equipped with a pulley which is driven by the accessory
drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler
pulleys may be provided to facilitate belt routing and alignment. The automatic belt tensioner
maintains correct belt tension and compensates for component wear and changes in system load.
System load changes can be caused by the A/C compressor clutch engaging and disengaging, or
demand changes on other systems powered by the accessory drive belt. To maintain correct
operation of this stem, it is critical that the correct length drive belt be installed. The pulleys must
also be correctly aligned and kept clean.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Inspection and Verification
CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys be
lubricated as potential damage to the belt material and tensioner damping mechanism will occur.
Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
Visual Inspection Chart
3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, power steering
cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered
acceptable. If damage exceeds the acceptable limit or
any chunks are found to be missing from the ribs, a new belt must be installed.
Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be
considered acceptable. If cracks exceed this standard, install a new belt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3240
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
6. The condition of the V-ribbed drive belt should be compared against the illustration and
appropriate action taken.
1. Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new
belt is not required. 2. Longer deposit areas building up to 50 percent of the rib height. This is not
considered a concern but it can result in excessive noise. If noise is
apparent, install a new belt.
3. Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a
new belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt. 8. If the concern is not visually evident, verify the symptom and
GO to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3241
Drive Belt: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3242
Drive Belt: Component Tests and General Diagnostics
Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of
a damaged or an incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on
an accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start-up and shut down or during very rapid
engine acceleration and decelerations, such as: ^
wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions.
^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual
transmissions.
These special short-term transient events are expected, and are due to the higher system inertial
required to meet the electrical and cooling demands on today's vehicle systems. Constant or
re-occurring drive belt squeal can occur under these conditions: ^
if the A/C discharge pressure goes above specifications: the A/C system is overcharged.
- the A/C condenser core airflow is blocked.
^ if the A/C OFF equalized pressure (the common discharged and suction pressure that occurs
after several minutes) exceeds specifications.
^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories
should be rotatable by hand in the unloaded condition, if not, inspect the accessory.
^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has
been exposed to fluid contamination during vehicle operation, such as leaks from the power
steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with
clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a
localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt
and pulleys should be washed with soap and water immediately (prior to starting the engine), and
rinsed with clean water.
^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive
belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will
release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.
^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.
Incorrect Drive Belt Installation
CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can
cause the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt
tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive
belt.
Incorrect Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3243
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the
accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur.
Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking
condition exists, proceed with the following: ^
Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface.
If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out
of position. This will result in chirp and squeal noises.
^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any
interference that would prevent the component from mounting correctly. Correct any interference
condition and recheck the accessory drive belt tracking.
^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware
to specification. Recheck the accessory drive belt tracking.
Belt Tensioner-Mechanical
The only mechanical check that needs to be made is a check for tensioner stick grab or bind. 1.
With the engine OFF, check routing of the accessory drive belt.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension
on the belt and detach the accessory drive belt in the area of the tensioner.
3. Using the suitable, commercially available serpentine belt tensioner release tool, move the
tensioner from its relaxed position, through its full
stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make
sure that there is tension on the tensioner spring.
4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
Install a new accessory drive belt tensioner if
necessary.
5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks. Install a new accessory drive
belt tensioner as necessary.
6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner
dynamically. If the accessory drive belt tensioner
does not meet the above criteria, install a new tensioner.
Belt Tensioner-Dynamics
The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine
running, observe the accessory drive belt tensioner movement. The accessory drive tensioner
should move (respond) when the air
conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory
drive belt tensioner movement is excessive without air conditioning clutch cycling or engine
acceleration, check belt ride-out. Excessive belt ride-out (uneven depth of grooves in the belt) can
cause excessive accessory drive belt tensioner movement. Check ride-out condition by installing a
new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory
drive belt tensioner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 3244
Drive Belt: Service and Repair
Accessory Drive
Removal
1. Rotate the drive belt tensioner clockwise and remove the drive belt.
Installation
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair
Drive Belt Tensioner: Service and Repair
Accessory Drive Belt Tensioner
Removal and Installation
1. Remove the cooling fan shroud.
2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from
the generator pulley. 3. Remove the 3 bolts and the accessory drive belt tensioner.
^ To install, tighten to 25 Nm (18 ft. lbs.).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 06-5-1 >
Mar > 06 > Engine Controls - Cold Start Rough Idle Condition
Engine Mount: Customer Interest Engine Controls - Cold Start Rough Idle Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 06-5-1 >
Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 3256
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition
Engine Mount: All Technical Service Bulletins Engine Controls - Cold Start Rough Idle Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: >
06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 3262
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3263
Engine Mount: Service and Repair
Engine Support Insulators
Special Tools And Equipment
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3264
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the air cleaner housing. 4. Remove the generator. 5. Remove the upper cooling fan
shroud. 6. If removing the RH engine support insulator, remove the starter. 7. If removing the LH
engine support insulator, remove the oil level indicator and tube.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3265
8. Install the special tools.
9. Remove the 4 exhaust manifold-to-catalytic converter nuts.
10. CAUTION: Only use hand tools when removing the transmission mount-to-crossmember nuts
or damage to the transmission mount can occur.
Loosen the transmission mount-to-crossmember nuts.
11. Remove the 4 bolts and position the sway bar down.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3266
12. CAUTION: Only use hand tools when removing the engine mount nut or damage to the engine
mount can occur.
Remove the RH engine mount nut.
13. CAUTION: Only use hand tools when removing the LH engine mount through bolt or damage to
the cage nut can occur.
NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using
service part number W709375. If the LH engine mount through bolt nut cage is damaged or
missing, remove the cage and install a new nut using service part number W520516-S301.
Remove the LH engine mount through bolt.
14. Using the special tools, raise the engine.
RH engine mount
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3267
15. Remove the 3 bolts and the engine mount.
LH engine mount
16. If servicing the LH engine mount on a 4WD vehicle, remove the front driveshaft.
17. Remove the 3 bolts and the engine mount.
Installation
RH engine mount
1. CAUTION: Clean the engine mount-to-cylinder block and engine mount-to-chassis mating
surfaces of any dirt or foreign material prior to
installation.
Position the RH engine mount and install the 3 bolts in the sequence shown. ^
Tighten to 63 Nm (46 ft. lbs.).
LH engine mount
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3268
2. CAUTION: Clean the engine mount-to-cylinder block and engine mount-to-chassis mating
surfaces of any dirt or foreign material prior to
installation.
Position the LH engine mount and install the 3 bolts in the sequence shown. ^
Tighten to 63 Nm (46 ft. lbs.).
3. If servicing the LH engine mount on a 4WD vehicle, install the front driveshaft.
All vehicles
4. Lower the engine into position.
5. CAUTION: Only use hand tools when removing the LH engine mount through bolt or damage to
the cage nut can occur.
NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using
service part number W709375. If the LH engine mount through bolt nut cage is damaged or
missing, remove the cage and install a new nut using service part number W520516-S301.
Install the LH engine support insulator bolt. ^
Tighten to 175 Nm (129 ft. lbs.).
6. CAUTION: Only use hand tools when installing the RH engine mount nut or damage to the
engine mount can occur.
Install the RH engine mount nut. ^
Tighten to 175 Nm (129 ft. lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3269
7. CAUTION: Only use hand tools when installing the transmission mount-to-crossmember nuts or
damage to the transmission mount can occur.
Install the transmission mount-to-crossmember nuts. ^
Tighten to 103 Nm (76 ft. lbs.).
8. Position the Y-pipe and install the four nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
9. Position the sway bar and install the 4 bolts.
^ To install, tighten to 30 Nm (22 ft. lbs.).
10. Remove the special tools. 11. If installing the LH engine mount, install the oil level indicator and
tube. 12. If installing the RH engine mount, install the starter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Technical Service Bulletins > Page 3270
13. Install the upper cooling fan shroud. 14. Install the generator. 15. Install the air cleaner housing.
16. Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair
Idler Pulley: Service and Repair
Accessory Drive Belt Idler Pulley
Removal and Installation
1. Remove the cooling fan shroud.
2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from
the generator pulley. 3. Remove the bolt and the accessory drive belt idler pulley.
^ To install, tighten to 25 Nm (18 ft. lbs.).
4. Repeat the previous step for each accessory drive belt idler pulley being serviced. 5. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
GENERAL SPECIFICATIONS
Oil pressure ........................................................................................ minimum at 517 kPa (75 psi)
2,000 rpm (engine at normal operating temperature)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 3278
Engine Oil Pressure: Testing and Inspection
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure
Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating
temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5.
The oil pressure should be within specifications; refer to the specification chart in the appropriate
engine section. 6. If the pressure is not within specification, check the following possible sources:
^ insufficient oil
^ oil leakage
^ worn or damaged oil pump
^ oil pump screen cover and tube
^ excessive main bearing clearance
^ excessive connecting rod bearing clearance
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube
Material
Material
Removal and Installation
1. With the vehicle in neutral, position it on a hoist. 2. Remove the oil level indicator and tube bolt.
^ To install, tighten to 10 Nm (89 inch lbs.).
3. Remove the oil level indicator and tube from the cylinder block.
^ Discard the O-ring seal.
4. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to
installation.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle
Engine Oil: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3290
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3291
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Customer Interest for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3292
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle
Engine Oil: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3298
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3299
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3300
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 6.6L (7.0 Qt)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 3303
Engine Oil: Fluid Type Specifications
Engnie Oil
U.S. ............................................................................................................................... Motorcraft
SAE 5W-20 Premium Synthetic Blend XO-5W20-QSP Canada
................................................................................................................. Motorcraft SAE 5W-20
Super Premium Mortor Oil CXO-5W20-LSP12
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Tools and Equipment
Oil Cooler: Tools and Equipment
3/8" Oil Cooler Line Remover
AST tool# 8021
Used for disconnecting transmission oil cooler lines. The flares on the the cooler lines near the
fittings prevent access with the original style disconnect tools. The locking clip used in the fitting is
different than the standard 'tabs' used on most other applications. The AST# 8021 will clear the
flare and disconnect the new style clips with ease.
- Fits 2004 and 2007 F150
- Used for R and R of Oil Cooler Lines
- Purple-Anodized Aluminum Construction
- Quick line removal
- See Application Chart
- Included in the 8107 and #8110 Line Disconnect Sets.
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
This Tool is also available in the following kits:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Tools and Equipment > Page 3307
8107 - 7-Piece Line Disconnect Set
8110 - 10-Pc. Line Disconnect Set
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle
Oil Filter: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3316
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3317
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > Customer Interest for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3318
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle
Oil Filter: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3324
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3325
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 3326
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair
Oil Filter Adapter: Service and Repair
Oil Filter Adapter
Material
Material
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine cooling system. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Disconnect the lower
radiator hose from the oil filter adapter and position it aside. 5. Disconnect the degas bottle hose
from the oil filter adapter and position it aside. 6. Remove and discard the engine oil filter. 7.
Remove the 4 bolts and the oil filter adapter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Page 3330
^ To install, tighten to 25 Nm (18 ft. lbs.).
8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive
means to clean the sealing surfaces. These may
cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces.
Remove and discard the oil filter adapter gasket. Clean the sealing surfaces with silicone gasket
remover and metal surface prep. Follow the directions on the packaging. Inspect the mating
surfaces.
9. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
TORQUE SPECIFICATIONS
Oil Pan bolts
Stage 1 ................................................................................................................................................
................................................. 2 Nm (18 inch lbs.) Stage 2 ...............................................................
................................................................................................................................... 20 Nm (15 ft.
lbs.) Stage 3 ........................................................................................................................................
................................................. an additional 60 degrees
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3334
Oil Pan: Service and Repair
Oil Pan
Material
Material
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil.
3. Remove the 4 bolts and the frame crossmember.
4. Remove the bolt and detach the wire harness bracket.
4WD vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3335
5. Support the front axle housing with a jack stand.
6. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation.
Remove the front axle housing RH mounting bolt.
7. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation.
Remove the front axle housing LH front mounting bolt.
8. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation
Remove the front axle housing LH rear mounting bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3336
9. CAUTION: Use care when lowering the front axle housing, or the vacuum lines to the axle
solenoid may become disconnected or damaged.
Lower the axle to allow clearance for the oil pan to be removed.
All vehicles
10. NOTE: Be careful when removing the oil pan gasket. It is reusable.
Remove the 16 bolts, the oil pan and the gaskets. ^
Inspect the oil pan gasket for damage.
^ If damaged, discard the oil pan gasket and the oil pan-to-oil pump gaskets.
Installation
All vehicles
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3337
2. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow
this procedure can cause future oil leakage.
Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing
surface.
3. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow
this procedure can cause future oil leakage.
Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3338
5. Tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60 degrees.
4WD vehicles
6. CAUTION: Use care when positioning the front axle housing, or the vacuum lines to the axle
solenoid may become disconnected or damaged.
Position the front axle housing and loosely install the three bolts, aligning the bolt location marks
made during removal.
7. Install the front axle housing RH mounting bolt.
^ Tighten to 89 Nm (66 ft. lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3339
8. Install the front axle housing LH front mounting bolt.
^ Tighten to 89 Nm (66 ft. lbs.).
9. Install the front axle housing LH rear mounting bolt.
^ Tighten to 89 Nm (66 ft. lbs.).
All vehicles
10. Position the frame crossmember and the 4 bolts.
^ Tighten to 102 Nm (75 ft. lbs.).
11. Install the wire harness bracket and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
12. Fill the crankcase with clean engine oil.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 3343
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair
Oil Pick Up/Strainer: Service and Repair
Oil Pump Screen and Pickup Tube
Material
Material
Removal
1. Remove the oil pan.
2. Remove the bolts, the oil pump screen and pickup tube and the spacer.
Installation
1. Install the oil pump screen and pickup tube spacer.
^ Tighten to 25 Nm (18 ft. lbs.).
2. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can
cause foam in the lubrication system, low oil
pressure and severe engine damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3350
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with
clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the bolts. ^
Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 inch lbs.).
^ Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 ft. lbs.).
3. Install the oil pan.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
GENERAL SPECIFICATIONS
Oil pressure ........................................................................................ minimum at 517 kPa (75 psi)
2,000 rpm (engine at normal operating temperature)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 3355
Engine Oil Pressure: Testing and Inspection
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure
Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating
temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5.
The oil pressure should be within specifications; refer to the specification chart in the appropriate
engine section. 6. If the pressure is not within specification, check the following possible sources:
^ insufficient oil
^ oil leakage
^ worn or damaged oil pump
^ oil pump screen cover and tube
^ excessive main bearing clearance
^ excessive connecting rod bearing clearance
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch,
Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
TORQUE SPECIFICATIONS
Intake Manifold Bolts Stage 1 ..............................................................................................................
...................................................................................... 2 Nm (18 inch lbs.). Stage 2 .........................
..............................................................................................................................................................
........... 10 Nm (89 inch lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly
Intake Manifold: Service and Repair Disassembly and Assembly
Intake Manifold Assembly
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3364
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3365
Disassembly
1. Remove the 4 bolts and the throttle body. 2. Remove the 4 bolts and the fuel rail. 3. Remove the
fuel injector-to-fuel rail locking clip and separate the fuel injectors from the fuel rail.
^ Discard the 2 O-ring seals from each fuel injector.
4. Remove the vacuum tube assembly from the intake manifold. 5. Remove the charge motion
control valve (CMCV) rod locking clips. 6. Remove the stud bolt, the 2 bolts and the CMCV. 7.
Remove the 2 bolts and the positive crankcase ventilation (PCV) heater element.
^ Discard the O-ring seal.
8. Remove the engine noise shield insulator from the intake manifold.
Assembly
1. Install the engine noise shield insulator onto the intake manifold.
2. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the positive crankcase ventilation (PCV) heater element and the 2
bolts. ^
Tighten to 6 Nm (53 inch lbs.).
3. Position the charge motion control valve (CMCV) and install the stud bolt and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
4. Install the CMCV rod locking clips. 5. Install the vacuum tube assembly onto the intake manifold.
6. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Install new O-ring seals on each of the fuel injectors.
7. Assemble the fuel injectors onto the fuel rail and install the locking clips. 8. Install the fuel rail
and fuel injector assembly onto the intake manifold. 9. Install the 4 fuel rail bolts.
^ Tighten to 10 Nm (89 inch lbs.).
10. Install the throttle body and tighten the bolts in two stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3366
^ Stage 2: Tighten an additional 90 degrees.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3367
Intake Manifold: Service and Repair Intake Manifold
Intake Manifold
Special Tools And Equipment
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3368
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3369
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3370
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not
running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel
system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or
a fire hazard.
1. Drain the cooling system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3371
2. Release the fuel system pressure. 3. Remove the generator. 4. Remove the air cleaner. 5.
Disconnect the upper radiator hose from the thermostat housing. 6. Disconnect the heater coolant
hose from the coolant bypass tube. 7. Disconnect the evaporative emissions system (EVAP) tube
from the intake manifold. 8. Remove the positive crankcase ventilation (PCV) tube. 9. Disconnect
the fuel supply spring lock coupling from the fuel rail.
10. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum
connector. 11. Disconnect the ~ fuel injector electrical connectors. 12. Disconnect the throttle
position (TP) sensor and electronic acceleration control electrical connectors.
13. Disconnect the heated PCV intake fitting electrical connector. 14. Disconnect the brake booster
vacuum hose from the intake manifold vacuum tube. 15. Remove the 10 intake manifold bolts
16. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Remove the 3 bolts, the coolant bypass tube and discard the gaskets. ^
Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the
packaging.
17. Disconnect the charge motion control valve (CMCV) electrical connector. 18. Disconnect the
manifold vacuum tube from the valve cover stud and the support bracket.
19. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3372
20. Disconnect the LH and RH knock sensor (KS) electrical connectors. 21. Remove the nut and
disconnect the engine wiring harness retainer from the CMCV stud.
22. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Remove the intake manifold and discard the gaskets. ^
Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the
packaging.
Installation
1. NOTE: Electrical and vacuum harnesses must not restrict movement of the charge motion
control valve (CMCV) control rods at rear of the intake
manifold. Use extreme care on installation of the intake manifold to prevent any pinching of
electrical and vacuum harnesses.
Using new intake manifold gaskets, position the intake manifold.
2. Using new gaskets, position the coolant crossover and install the 3 bolts
^ Tighten to 10 Nm (89 inch lbs.).
3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).
4. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
5. Connect the CMCV electrical connector.
6. Connect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Disassembly and Assembly > Page 3373
7. Connect the LH and RH knock sensor (KS) electrical connectors. 8. Connect the manifold
vacuum tube to the support bracket and the valve cover stud and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
9. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
10. Connect the heated positive crankcase ventilation (PCV) intake fitting electrical connector. 11.
Connect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
12. Connect the 8 fuel injector electrical connectors. 13. Connect the fuel rail pressure and
temperature sensor electrical connector and vacuum connector. 14. Connect the fuel supply spring
lock coupling from the fuel rail. 15. Install the PCV tube. 16. Connect the evaporative emissions
system (EVAP) tube to the intake manifold. 17. Connect the heater coolant hose to the coolant
bypass. 18. Connect the upper radiator hose to the thermostat housing. 19. Install the generator.
20. Install the air cleaner. 21. Fill and bleed the engine cooling system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Seal with Retainer Plate
Special Tools And Equipment
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3378
Material
Material
Removal
1. Remove the transmission. 2. Remove the 8 bolts and the flexplate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3379
3. Using the special tools, remove the crankshaft oil slinger.
^ Discard the crankshaft oil slinger.
4. Using the special tools, remove the crankshaft rear seal.
^ Discard the crankshaft rear seal.
5. Remove the 2 oil pan-to-crankshaft rear seal retainer plate bolts. 6. Remove the 6 bolts and the
crankshaft rear seal retainer plate.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Clean and inspect the mating surface.
2. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant
must be removed and the sealing area cleaned with
metal surface cleaner. Allow to dry until there is no sign of wetness or 4 minutes, whichever is
longer. Failure to follow this procedure can cause future oil leaks.
NOTE: The silicone must be applied on the groove along the retainer plate.
Apply a 4.06-mm (0.16-inch) bead of silicone gasket and sealant around the crankshaft rear seal
retainer plate sealing surface.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3380
3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
4. Install the 2 crankshaft rear seal retainer plate-to-oil pan bolts and tighten in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.
5. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install the crankshaft rear seal.
6. Using the special tools, install the crankshaft rear oil slinger.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3381
7. Install the flexplate and tighten the 8 bolts in the sequence shown.
^ Tighten to 80 Nm (59 ft. lbs.).
8. Install the transmission.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification
Cylinder Head Gasket: 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 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3386
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3387
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3388
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 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Crankshaft Front Seal
Special Tools And Equipment, Part 1
Special Tools And Equipment, Part 2
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 3392
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the engine cooling fan lower
shroud.
3. Rotate the tensioner clockwise and remove the accessory drive belt. 4. Remove the crankshaft
pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 3393
6. Using the special tool, remove the crankshaft front seal.
Installation
1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal.
3. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area
cleaned with metal surface prep and silicone gasket
remover. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure
to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 3394
4. Using the special tool, install the crankshaft pulley.
5. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
6. Rotate the tensioner clockwise and install the accessory drive belt. 7. Install the engine cooling
fan lower shroud.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Valve Seals
Special Tools And Equipment
Special Tool(s)
Material
Material
Removal
1. Depending on the valve being serviced, remove the LH or RH valve cover. 2. Remove the spark
plug. 3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke
with the intake valve and the exhaust valves closed.
4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position.
^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 3398
6. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder.
If air pressure must be removed, support the valve prior to removal.
CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for locations.
NOTE: If a valve drops into the cylinder, remove the cylinder head.
Using the special tool, compress the valve spring and remove the valve spring retainer keys.
7. Remove the valve spring retainer, the valve spring and the valve seal.
^ Discard the valve seal.
8. Inspect the components.
Installation
1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Using the special tool, install a new valve seal.
2. Using the special tool, install the valve spring, the valve spring retainer and the valve spring
retainer keys. 3. Relieve the air pressure from the cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 3399
4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Using the special tool, compress the valve spring and install the camshaft roller follower.
5. Install the spark plug. 6. Depending on the valve being serviced, install the LH or RH valve
cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 3404
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor
> Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
TORQUE SPECIFICATIONS
LH and RH Camshaft Phaser Sprocket Bolts
Stage 1 ................................................................................................................................................
.................................................. 40 Nm (30 ft. lbs.) Stage 2 ................................................................
............................................................................................................................. additional 90
degrees.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications > Page 3415
Camshaft Gear/Sprocket: Service and Repair
Special Tool(s)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional
information, refer to Camshaft - RH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional
information, refer to Camshaft - LH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See:
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
- If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
- If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications > Page 3416
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Installation
1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to
valves and pistons will result.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional
information, refer to Camshaft - RH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional
information, refer to Camshaft - LH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Timing Drive Components
Special Tool(s)
Material
Material
Removal
1. Remove the engine front cover.
2. Remove the crankshaft sensor ring from the crankshaft.
3. Position the crankshaft keyway at the 12 o'clock position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3420
4. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one
full additional rotation to 12 o'clock.
The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by
noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder.
5. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
6. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3421
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove the 3 designated roller followers in the previous step from the RH
cylinder head.
7. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations.
Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
8. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3422
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove the 3 designated roller followers in the previous step from the LH
cylinder head.
9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set.
Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
10. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the
tensioner-sealing bead must be inspected for seal
integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal
bead is observed, install a new tensioner or engine damage may occur.
Remove the bolts, the LH timing chain tensioner and tensioner arm.
11. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the
tensioner-sealing bead must be inspected for seal
integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal
bead is observed, install a new tensioner or engine damage may occur.
Remove the bolts, the RH timing chain tensioner and tensioner arm.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3423
12. Remove the RH and LH timing chains and the crankshaft sprocket.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain from the crankshaft sprocket.
^ Remove the LH timing chain from the camshaft sprocket.
^ Remove the LH timing chain and crankshaft sprocket.
13. NOTE: RH shown, LH similar.
Remove the LH and RH timing chain guides. ^
Remove the bolts.
^ Remove both timing chain guides.
14. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3424
CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may
occur to the camshaft or camshaft phaser unit.
Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly. ^
Discard the camshaft phaser sprocket bolt.
15. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may
occur to the camshaft or camshaft phaser unit.
Using the special tool, remove the bolt and the LH camshaft phaser and sprocket assembly. ^
Discard the camshaft phaser sprocket bolt.
16. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from
sideloading.
Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
17. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.
Remove the remaining 8 bolts in the sequence shown and remove the RH cylinder head camshaft
bearing caps.
18. Clean and inspect the RH camshaft bearing caps.
The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3425
19. Remove the RH camshaft.
20. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from
sideloading.
Remove the 2 bolts and the LH cylinder head camshaft bearing cap.
21. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.
Remove the remaining 8 bolts in the sequence shown and remove the LH cylinder head camshaft
bearing caps.
22. Clean and inspect the LH camshaft bearing caps.
The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
23. Remove the LH camshaft.
24. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into the
original locations. Failure to follow these instructions may result in engine damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3426
Remove all of the remaining roller followers from the cylinder heads.
Installation
1. Install the LH and RH camshafts.
^ Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
2. NOTE: LH shown, RH similar.
Install the LH and RH camshaft bearing caps in their original locations. ^
Lubricate the camshaft bearing caps with clean engine oil.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
^ Tighten to 10 Nm (89 inch lbs.). in the sequence shown.
3. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
NOTE: LH shown, RH similar.
Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3427
4. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may
occur to the camshaft or camshaft phaser unit.
NOTE: LH shown, RH similar.
Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages. ^
Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
5. Using the special tool, position the crankshaft keyway at the 11 o'clock position.
6. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons
will result.
CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears,
separation from the tensioner body or permanent compression of the seal bead is observed, install
a new tensioner.
Compress the tensioner plunger, using a vise.
7. Install a retaining clip on the tensioner to hold the plunger in during installation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3428
8. Remove the tensioner from the vise.
9. If the copper links are not visible, mark two links on one end and one link on the other end, and
use as timing marks.
10. Install the crankshaft sprocket, making sure the flange faces forward.
11. Install the 4 bolts and the LH and RH timing chain guides.
^ Tighten to 10 Nm (89 inch lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3429
12. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the
timing mark on the outer flange of the crankshaft
sprocket with the single copper (marked) link on the chain.
13. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark
positioned between the two copper (marked) chain links.
14. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain
tensioner and bolts. ^
Tighten to 25 Nm (18 ft. lbs.).
15. Remove the retaining clip from the LH timing chain tensioner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3430
16. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the
timing mark on the sprocket with the single copper
(marked) chain link.
17. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
NOTE:The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks
for the RH camshaft.
Position the RH timing chain on the camshaft phaser and sprocket wil the timing mark positioned
between the 2 copper (marked) chain links.
18. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain
tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3431
19. Remove the retaining clip from the RH timing chain tensioner.
20. As a post-check, verify correct alignment of all timing marks.
21. Install the crankshaft sensor ring on the crankshaft.
22. NOTICE: If the components are to be reinstalled, they must be installed into their original
locations. Failure to follow these instructions may
result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valave drops into the cylinder, the cylinder head must be removed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3432
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the speical tool, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation.
23. Install the engine front cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
TORQUE SPECIFICATIONS
CHAIN TENSIONER
Left Hand Timing Chain Tensioner Bolts
................................................................................................................................................. 25 Nm
(18 ft. lbs.) Right Hand Timing Chain Tensioner Bolts
.............................................................................................................................................. 25 Nm
(18 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
TORQUE SPECIFICATIONS
ENGINE FRONT COVER
Engine Front Cover Bolts
Stage 1
.............................................................................................................................................................
fasteners 1 through 15, 25 Nm (18 ft. lbs.) Stage 2 .............................................................................
.......................................................................................... fasteners 6 and 7, 8 Nm (35 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3439
Timing Cover: Service and Repair
Engine Front Cover
Special Tools And Equipment
Special Tool(s)
Material, Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3440
Material, Part 2
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3441
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3442
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. 3. Remove the
engine cooling fan. 4. Remove the RH valve cover. 5. Remove the LH valve cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3443
6. Rotate the tensioner clockwise and remove the accessory drive belt.
7. Remove the nut and the power steering pressure hose support bracket.
8. Remove the nut and the transmission cooler tube support bracket. 9. Remove the crankshaft
pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
10. Using the special tool, remove the crankshaft pulley.
11. Using the special tool, remove the crankshaft front seal. 12. Remove the 3 bolts and the 3
accessory drive idler pulleys. 13. Remove the 4 bolts and the coolant pump pulley.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3444
14. Remove the 3 bolts and the accessory drive belt tensioner. 15. Disconnect the RH camshaft
position (CMP) sensor electrical connector. 16. Remove the bolt and the RH CMP sensor.
^ Discard the O-ring seal.
17. NOTE: LH shown, RH similar
Disconnect the radio ignition interference capacitor electrical connectors.
18. Remove the nut and the RH radio ignition interference capacitor. 19. Disconnect the LH CMP
sensor electrical connector. 20. Remove the bolt and the LH CMP sensor.
^ Discard the O-ring seal.
21. Remove the nut and the LH radio ignition interference capacitor. 22. Remove the bolts and
position the power steering pump assembly aside. 23. Disconnect the crankshaft position (CKP)
sensor electrical connector. 24. Remove the 4 front oil pan bolts. 25. Remove the bolt and the CKP
sensor.
^ Discard the O-ring seal.
26. Remove the bolts and the studs.
27. 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 gaskets.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3445
^ Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.
^ Inspect the mating surfaces.
Installation
1. Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and
the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface
prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil
leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before
installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and
the oil pan-to-cylinder block surface, at the locations shown.
3. Install a new engine front cover gasket on the engine front cover. Position the engine front cover
onto the dowels. Install the fasteners finger tight.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3446
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3447
4. Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.). Stage 2: Tighten fasteners 6 and 7
to 48 Nm (35 ft. lbs.).
5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.
6. Connect the CKP sensor electrical connector. 7. Position the power steering pump assembly
and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
8. Position the power steering pressure hose support bracket and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3448
9. Position the transmission cooler tube support bracket and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
10. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the RH CMP sensor and the bolt. ^
Tighten to 10 Nm (89 inch lbs.).
11. Connect the RH CMP sensor electrical connector. 12. Install the LH radio ignition interference
capacitor and the nut.
^ Tighten to 10 Nm (89 inch lbs.).
13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the LH CMP sensor and the bolt. ^
Tighten to 10 Nm (89 inch lbs.).
14. Connect the LH CMP sensor electrical connector. 15. Install the RH radio ignition interference
capacitor and the nut.
^ Tighten to 10 Nm (89 inch lbs.).
16. NOTE: LH shown, RH similar
Connect the radio ignition interference capacitor electrical connectors.
17. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
18. Install the coolant pump pulley and the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
19. Install the 3 accessory drive idler pulleys and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3449
20. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
21. Using the special tools, install the crankshaft seal into the engine front cover.
22. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone gasket
remover and metal surface prep. Follow the directions on the packaging. Failure to follow this
procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
23. Use the special tool to install the crankshaft pulley.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3450
24. Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
25. Rotate the tensioner clockwise and install the accessory drive belt. 26. Install the RH valve
cover. 27. Install the LH valve cover. 28. Install the engine cooling fan. 29. Fill the crankcase with
clean engine oil.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3460
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3461
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3462
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Valve Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Valve Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3467
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Variable Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up
Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Variable Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3473
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Variable Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3474
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Variable Valve Timing Actuator: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 3475
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
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Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Variable Valve Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Variable Valve Timing Actuator: > 05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 3480
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
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Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page
3483
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Page 3484
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAM TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At
idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air
flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the
PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems
provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS
systems also have the added benefit of improved torque. In addition, some VCT system
applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The
elimination of the EGR system is accomplished by controlling the overlap time between the intake
valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used.
Variable Cam Timing (VCT) System
Variable Cam Timing System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments.
1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant
temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system will not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It will continually update the
VCT solenoid duty cycle until the desired position is achieved. A difference between the desired
and actual camshaft position represents a position error in the PCM VCT control loop. The PCM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Page 3485
will disable the VCT and place the camshaft in a default position if a fault is detected. A related
DTC will also be set when the fault is detected.
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the cam timing. One
half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing
chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow
of oil is shifted from one side of the chamber to the other, the differential change in oil pressure
forces the camshaft to rotate in either a advance or retard position depending on the oil flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Service and Repair
Variable Valve Timing Solenoid: Service and Repair
VARIABLE CAMSHAFT TIMING OIL CONTROL SOLENOID
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the variable camshaft timing (VCT) oil
control solenoid electrical connector. 3. Remove the VCT oil control solenoid grommet. 4. Remove
the bolt and the VCT oil control solenoid. Discard the O-ring seal.
- To install, tighten to 5 Nm (44 lb-in).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Description and Operation
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that
relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic
procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and
HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel
Pressure Test Kit #134-R0087 or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
.......................................................... 600 - 650 RPM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
AIR CLEANER INTAKE PIPE
Exploded View
Removal and Installation
1. Remove the air cleaner element.
2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air
cleaner intake pipe to release the air cleaner intake pipe
from the air cleaner assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3501
3. Remove the air cleaner intake tube assembly.
4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Exploded View
Removal and Installation
1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner
element from the air cleaner element tray.
3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure
to do so will result in unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
Item ......................................................................................................................................................
............................................................ Specification
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System MIL ON/DTC P0300-P0308/P0316
Spark Plug: Customer Interest Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System MIL ON/DTC P0300-P0308/P0316 > Page 3524
BASIC PART NO. CODE
12405 42
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL
ON/Rough Idle/Long Crank/Misfire/DTC's
Spark Plug: Customer Interest Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
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Plug > Component Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL
ON/Rough Idle/Long Crank/Misfire/DTC's > Page 3529
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL
ON/Rough Idle/Long Crank/Misfire/DTC's > Page 3530
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL
ON/Rough Idle/Long Crank/Misfire/DTC's > Page 3531
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-25-4 >
Dec > 08 > Ignition System - MIL ON/DTC P0300-P0308/P0316
Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-25-4 >
Dec > 08 > Ignition System - MIL ON/DTC P0300-P0308/P0316 > Page 3537
BASIC PART NO. CODE
12405 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3542
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3543
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3544
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3545
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3546
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3547
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3548
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3549
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3550
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3551
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr
> 08 > Ignition System - Spark Plug Removal Instructions > Page 3552
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 >
Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
Spark Plug: All Technical Service Bulletins Fuel System - MIL ON/Rough Idle/Long
Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
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Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 3557
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 >
Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 3558
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 >
Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 3559
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3565
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3566
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3567
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3568
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3569
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3570
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
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Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3571
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3572
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3573
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3574
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr >
08 > Ignition System - Spark Plug Removal Instructions > Page 3575
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap
Spark Plug: Specifications Gap
Spark Plug Gap ...................................................................................................................................
.................................0.040 - 0.50 in (1.02 - 1.27 mm)
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Plug > Component Information > Specifications > Gap > Page 3578
Spark Plug: Specifications Torque
Spark Plug Torque ...............................................................................................................................
.........................................................34 Nm (25 ft-lb)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3579
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
.................................................................... PZT-2FE
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Plug > Component Information > Service and Repair > Removal and Installation
Spark Plug: Service and Repair Removal and Installation
SPARK PLUGS
Engine Ignition - RH
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Engine Ignition - LH
Exploded View
Removal and Installation
1. Remove the ignition coil-on-plug.
2. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal
procedure.
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Plug > Component Information > Service and Repair > Removal and Installation > Page 3583
Spark Plug: Service and Repair Spark Plug-Inspection
Spark Plug-Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or wont or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
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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 3584
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a Heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
GENERAL SPECIFICATIONS
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3588
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3589
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
GENERAL SPECIFICATIONS
Valves
Valve stem-to-guide clearance - intake
.......................................................................................................................... 0.020-0.045
mm(0.001-0.002 in) Valve stem-to-guide clearance - exhaust
........................................................................................................................ 0.069-0.094
mm(0.003-0.004 in) Valve head diameter intake
............................................................................................................................................
33.62-33.98 mm(1.324-1.338 in) Valve head diameter exhaust
................................................................................................................................... 37.32-37.68
mm(1.469-1.483 in) Valve face runout ................................................................................................
................................................................................ 0.05 mm (0.002 in) Valve face angle ..................
..............................................................................................................................................................
............. 45.5 degrees Valve seat width intake
..........................................................................................................................................................
1.2-1.4 mm (0.047-0.055in) Valve seat width exhaust
........................................................................................................................................................
1.4-1.6 mm (0.055-0.063in) Valve seat angle .....................................................................................
................................................................................................ 44.5-45.0 degrees Valve spring free
length ...................................................................................................................................................
..................... 55.7 mm (2.19 in) Valve spring compression pressure
................................................................................................. 350 N (79 lbs) ± 17.5 N(4 lbs) (a
42.04 mm (1.66in) Valve spring installed height ..................................................................................
............................................................................. 42.04 mm (1.66 in) Valve spring installed
pressure ..................................................................................................... 350 N (79 lbs) ± 17.5 N
(4 lbs) @ 42.04 mm (1.66 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
TORQUE SPECIFICATIONS
Coolant Pump Bolts .............................................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3596
Water Pump: Service and Repair
Coolant Pump
Material
Material
Removal and Installation
1. Drain the engine cooling system. 2. Remove the cooling fan. 3. Remove the accessory drive
belt. 4. Remove the 4 bolts and the coolant pump pulley.
^ To install, tighten to 25 Nm (18 ft. lbs.).
5. Remove the four bolts and the coolant pump. Discard the O-ring seal.
^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
^ Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation.
^ To install, tighten to 25 Nm (18 ft. lbs.).
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Service and Repair
Thermostat Bypass Hose: Service and Repair
Bypass Tube
Material
Material
Removal and Installation
1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Remove the three bolts, the
bypass tube, and discard the bypass tube gaskets.
^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
^ Install new bypass tube gaskets.
^ To install, tighten to 10 Nm (89 inch lbs.).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Cooling System Capacity
Base Radiator Without Aux Rear Heat ................................................................................................
................................................................ 19.4 quarts (18.4 liters) With Aux Rear Heat ......................
............................................................................................................................................... 20.7
quarts (19.6 liters)
Heavy Duty Trailer Tow Without Aux Rear Heat .................................................................................
............................................................................... 19.7 quarts (18.6 liters) With Aux Rear Heat .......
..............................................................................................................................................................
20.9 quarts (19.8 liters)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 3605
Coolant: Fluid Type Specifications
Coolant Types
Motorcraft Premium Gold Engine Coolant (yellow color). VC-7-A (US, except CA, OR and NM)
VC-7-B (CA, OR and NM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair
Coolant Reservoir: Service and Repair
Degas Bottle
Material
Material
Removal and Installation
1. Drain the engine cooling system. 2. Disconnect the two coolant hoses from the degas bottle. 3.
Remove the two bolts and the degas bottle.
^ To install, tighten to 9 Nm (80 inch lbs.).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Description and Operation
Radiator Cooling Fan Motor: Description and Operation
FAN CONTROL
Five Hundred/Freestyle/Montego, Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle
Output From PCM (negative Duty Cycle)
LS, Thunderbird: FCV Duty Cycle Output From PCM
The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C
on/off status, A/C pressure) to determine engine cooling fan needs.
For variable speed electric fan(s):
The PCM controls the fan speed and operation using a duty cycle output on the fan control variable (FCV) circuit. The fan controller (located at or integral to the engine cooling fan assembly)
receives the FCV command and operates the cooling fan at the speed requested (by varying the
power applied to the fan motor).
For relay controlled fans:
The PCM controls the fan operation through the fan control (FC) (single speed fan applications),
low fan control (LFC), medium fan control (MFC), and/or high fan control (HFC) outputs. Some
applications will have the xFC circuit wired to 2 separate relays.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Description and Operation > Page 3613
2.0L Focus (with A/C) And Taurus/Sable: PCM FC Output State For Cooling Fan Speeds Chart
2.0L Escape: PCM FC Output State For Cooling Fan Speeds Chart
Freestar, Monterey: PCM FC Output State For Cooling Fan Speeds Chart
For 3-speed fans, although the PCM output circuits are called low, medium, and high tan control
(FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair
Fan Blade: Service and Repair
Cooling Fan-Blade, Clutch and Shroud
Special Tools And Equipment
Special Tool(s)
Removal and Installation
1. Remove the air cleaner inlet pipe and resonator. 2. Remove the two bolts and the lower cooling
fan shroud.
^ To install, tighten to 3 Nm (27 inch lbs.).
3. Remove the two bolts and the upper cooling fan shroud.
^ To install, tighten to 3 Nm (27 inch lbs.).
4. Using the special tools, remove the cooling fan assembly.
^ To install, tighten to 55 Nm (41 ft. lbs.).
^ If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Fan Clutch.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection
Fan Clutch: Testing and Inspection
Fan Clutch Test-Maximum Speed Requirement
1. Carry out Steps 1 through 5 of the Fan Clutch Test-Minimum Speed Requirement.
2. NOTE: The temperature of air in front of the clutch should be above 96°C (205°F) for maximum
fan speed.
Block off areas on each side of the radiator in the engine compartment and the front of the radiator
grille. This will raise the temperature of the air striking the fan clutch and should cause the fan
blade to operate at maximum speed.
3. On the electronic manual temperature control (EMTC), select panel mode, with A/C and
recirculation buttons requested ON. On the electronic
automatic temperature control (EATC), select panel mode, with A/C and recirculation buttons ON
and the blower motor switch in the HI position.
4. Adjust the strobe to 3,000 rpm.
5. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate
the engine until the fan blade has been
first examined for possible cracks and separation.
Start the engine and adjust the engine speed until the digital photoelectric tachometer light and the
water pump pulley mark are synchronized.
6. Aim the digital photoelectric tachometer light at the fan blade retaining bolts. Adjust the digital
photoelectric tachometer light until the light flash
is synchronized with the marked fan blade bolt (the fan blade appears to stand still).
7. If the fan blade speed is less than 2,300 rpm, install a new fan clutch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Service and Repair > Cooling Fan-Blade, Clutch and Shroud Removal and Installation
Fan Clutch: Service and Repair Cooling Fan-Blade, Clutch and Shroud Removal and Installation
Cooling Fan-Blade, Clutch and Shroud
Special Tools And Equipment
Special Tool(s)
Removal and Installation
1. Remove the air cleaner inlet pipe and resonator. 2. Remove the two bolts and the lower cooling
fan shroud.
^ To install, tighten to 3 Nm (27 inch lbs.).
3. Remove the two bolts and the upper cooling fan shroud.
^ To install, tighten to 3 Nm (27 inch lbs.).
4. Using the special tools, remove the cooling fan assembly.
^ To install, tighten to 55 Nm (41 ft. lbs.).
^ If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Fan Clutch.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Service and Repair > Cooling Fan-Blade, Clutch and Shroud Removal and Installation > Page
3622
Fan Clutch: Service and Repair Cooling Fan and Fan Clutch Disassembly and Assembly
DISASSEMBLY AND ASSEMBLY
Cooling Fan and Fan Clutch
Disassembly and Assembly
1. Remove the four cooling fan-to-cooling fan clutch bolts and separate the clutch from the cooling
fan.
^ To assemble, tighten to 17 Nm (13 ft. lbs.).
2. To assemble, reverse the disassembly procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Service and Repair > Page 3623
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 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 3628
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3631
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Description and Operation > Page 3632
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Temperature Sensor (Gauge) > Component Information > Description and Operation
Temperature Sensor (Gauge): Description and Operation
Temperature Gauge
The PCM receives the engine coolant temperature status through hardwired circuitry to the engine
coolant temperature (ECT) sensor. The instrument cluster receives the engine coolant temperature
data from the PCM through the SCP communication network. The instrument cluster
microprocessor monitors the engine coolant temperature data received from the PCM and
commands the temperature gauge indication with a corresponding movement of the pointer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Cooling Fan-Blade, Clutch and Shroud
Special Tools And Equipment
Special Tool(s)
Removal and Installation
1. Remove the air cleaner inlet pipe and resonator. 2. Remove the two bolts and the lower cooling
fan shroud.
^ To install, tighten to 3 Nm (27 inch lbs.).
3. Remove the two bolts and the upper cooling fan shroud.
^ To install, tighten to 3 Nm (27 inch lbs.).
4. Using the special tools, remove the cooling fan assembly.
^ To install, tighten to 55 Nm (41 ft. lbs.).
^ If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Fan Clutch.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 3647
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 5 (2005))
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 3648
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 5 (2005))
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 5 (2005))
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 3654
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 5 (2005))
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 3655
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 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3656
Heater Core: Description and Operation
HEATER CORE
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer the heat to air passing through the plenum.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3657
Heater Core: Testing and Inspection
HEATER CORE
WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate
the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to
vent the exhaust gases outside the closed area.
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were
good and did not require replacement. If a heater
core leak is suspected, the heater core must be tested by carrying out the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking
the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core - Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is working
correctly.
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose
to see if it is hot.
If it is not hot: -
the heater core may have an air pocket.
- the heater core may be plugged.
- the thermostat is not working correctly.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter
BT-7422-A from the Radiator/Heater Core
Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of 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 perform the bench test.
Heater Core - Bench Test
1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3.
Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes.
Then connect the Radiator/Heater Core Pressure
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3658
Tester to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heating and Ventilation
Heater Core: Service and Repair Heating and Ventilation
HEATER CORE
REMOVAL
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
1. Remove the plenum chamber.
2. Remove the dash panel seal.
3. Remove the screws and the heater core cover. 4. Remove the heater core.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heating and Ventilation > Page 3661
Heater Core: Service and Repair Auxiliary Climate Control
HEATER CORE
Removal and Installation
1. Remove the auxiliary climate control housing.
2. Remove the screws and the evaporator/heater core access cover.
3. Remove the heater core. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 3670
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 5 (2005))
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 3671
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 5 (2005))
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 5 (2005))
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 3677
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 5 (2005))
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 3678
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 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling
Heater Hose: Service and Repair Heater Hose Coupling
HEATER HOSE COUPLING
Remover, Heater Hose Inlet Tube
Special Tool(s)
Disconnect
1. WARNING: The engine must be off, fully cool and the cooling system fully depressurized before
attempting to disconnect any heater
water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid
escaping out of the engine cooling system.
Depressurize the engine cooling system.
2. Push the heater water hose toward the tube to fully expose the locking tabs.
3. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must
be perpendicular to and on the highest point of the
coupling.
Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to
assist in the removal.
Pull the heater water hose away from the heater core tube.
5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling > Page 3681
7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer.
Connect
1. Clean the tubes and lubricate with MERPOL(R) meeting Ford specification ESE-M99B144-B or
plain water.
2. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect
coupling housing.
3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the
coupling is fully engaged by lightly pulling on the heater water hose.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling > Page 3682
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE
Removal
CAUTION: To avoid refrigerant loss, clearly differentiate the auxiliary heater lines from the auxiliary
refrigerant lines before beginning this procedure.
NOTE:
- The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary
heater inlet line and outlet line are each installed from the factory as one piece assemblies. The
replacement parts are supplied as separate kits containing multiple piece lines for ease of
installation.
- The following procedure can be used to remove and install one of, or both the auxiliary heater
inlet line and auxiliary heater outlet line. If only one auxiliary heater line is to be removed and
installed, cut or disconnect only the desired line at the specified points within the procedure.
1. Drain the engine coolant. 2. Remove the RH quarter trim panel.
3. Detach the auxiliary heater lines.
1 Disconnect the heater hose(s).
2 Remove the bolts.
3 Remove the line bracket.
4. Remove the spare tire. 5. Raise the vehicle. 6. Remove the RH front wheel. 7. Remove the RH
fender splash shield.
8. NOTE: If installing only one auxiliary heater line, disconnect only the desired line.
Disconnect the heater hose(s).
9. Remove the muffler.
10. Remove the RH catalytic converter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling > Page 3683
11. Remove the three bolts and the heat shield.
12. Remove the bolts.
13. Remove the nut and the line bracket.
14. Remove the bolt and the heat shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling > Page 3684
15. Remove the nuts and the remaining line brackets.
16. NOTE: If installing only one auxiliary heater line, cut only the desired line.
Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using
a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s).
17. Remove the auxiliary heater line(s) in three separate pieces.
Installation
1. Partially lower the vehicle.
2. Attach the rear portion of the auxiliary heater lines.
1 Connect the heater hoses.
2 Install the line bracket.
3 Install the bolts.
3. Install the front auxiliary heater line(s) and connect the heater hose(s).
- Clean and lubricate the heater hoses with plain water only if needed.
4. Raise the vehicle.
5. NOTE: Loosely connect, but do not tighten, the fittings.
Install the middle auxiliary heater line(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling > Page 3685
6. Starting from the rear of the vehicle, install the first three line brackets. 7. Tighten the middle
auxiliary heater line fittings. 8. Inspect the auxiliary heater lines for correct installation. Loosen,
reposition and tighten as needed.
9. Install the heat shield and the bolts.
10. Install the heat shield and the bolts. 11. Install the RH catalytic converter. 12. Install the muffler.
13. Partially lower the vehicle.
14. Install the heat shield bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hose Coupling > Page 3686
15. Install the line bracket. 16. Lower the vehicle. 17. Install the spare tire. 18. Install the RH
quarter trim panel. 19. Fill the engine coolant level.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Diagrams > Page 3690
Radiator: Testing and Inspection
Radiator Leak Test, Removed From Vehicle
CAUTION: Never leak test an aluminum radiator in the same water that copper/brass radiators are
tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage
aluminum radiators.
NOTE: Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator.
1. Leak test the radiator in clean water with 138 kPa (20 psi) air pressure.
Fan Clutch Test
1. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high
resistance, the minimum and maximum fan
speeds must be checked as follows:
Fan Clutch Test-Minimum Speed Requirement
1. Use a suitable marker to mark the coolant pump pulley, one of the fan blade retaining bolts and
the crankshaft pulley. 2. Connect a tachometer to the engine. 3. Install a throttle adjusting tool. 4.
Connect a digital photoelectric tachometer.
5. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate
the engine until the fan blade has been
first examined for possible cracks and separation.
Start the engine and run it at approximately 1,500 rpm until the normal operating temperature has
been achieved. The A/C must be off.
6. Adjust the engine speed to 2,300 rpm. 7. Operate the digital photoelectric tachometer at 3,000
rpm and aim it at the coolant pump pulley. Adjust the engine speed until the light flash and
the coolant pump pulley mark are synchronized.
8. Aim the digital photoelectric tachometer at the fan blade bolts. Adjust the strobe light until the
light flash is synchronized with the marked fan
blade bolt (the fan blade appears to stand still).
9. The fan blade speed must not be greater than 1,500 rpm at 3,000 coolant pump rpm.
10. Turn the engine off. 11. If the fan blade speed was greater than 1,500 rpm, install a new fan
clutch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Diagrams > Page 3691
Radiator: Service and Repair
Radiator
Special Tools And Equipment
Special Tool(s)
Material
Material
Removal and Installation
1. Drain the engine cooling system.
2. Remove the pin-type retainers and the air deflector cover. 3. Remove the cooling fan and
shroud. 4. Disconnect the upper radiator coolant hose from the radiator. 5. Disconnect the degas
bottle return hose from the radiator. 6. Disconnect the lower radiator coolant hose from the radiator.
7. Push the special tool into the fitting to release the tube retaining clip and remove the
transmission cooler lines from the radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Diagrams > Page 3692
8. Remove the two bolts and the two radiator support brackets.
^ To install, tighten to 30 Nm (22 ft. lbs.).
9. Remove the radiator and the four radiator insulators.
10. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
3698
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and
Operation > CHT Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3701
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3702
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Description and
Operation
Temperature Sensor (Gauge): Description and Operation
Temperature Gauge
The PCM receives the engine coolant temperature status through hardwired circuitry to the engine
coolant temperature (ECT) sensor. The instrument cluster receives the engine coolant temperature
data from the PCM through the SCP communication network. The instrument cluster
microprocessor monitors the engine coolant temperature data received from the PCM and
commands the temperature gauge indication with a corresponding movement of the pointer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Testing and Inspection
Thermostat: Testing and Inspection
Thermostat
A new thermostat should be installed only after the following electrical and mechanical tests have
been carried out.
Thermostat-Electrical Test
NOTE: The electrical thermostat test is most accurate if carried out indoors at less than 37.8°C
(100°F) ambient air. This test may be carried out with or without the hood open and with the engine
warm or cold.
1. Check the engine coolant level. Fill as needed. 2. With the ignition OFF, voltage values (0-5 V)
may now be monitored while the cylinder head temperature (CHT) sensor retains its connection to
the wiring harness. A scan tool may be used to monitor the CHT on vehicles equipped with data
link connector (DLC). The SBDS sequence to use for the screen is: Toolbox-Electronic Engine
Control and DCL-Item.
3. Place the automatic transmission in PARK (P) or the manual transmission in NEUTRAL (N) and
engage the parking brake. 4. Start the engine and allow the engine to idle throughout this test.
Allow the engine to run for two minutes, then record the CHT voltage. Record the
CHT voltage every 60 seconds. When the CHT voltage trend changes direction or only changes
slightly (0.03 volt or less) from the previous reading, record this as the thermostat opening voltage.
Use the voltage and corresponding coolant temperature chart listed below.
5. If the coolant thermostat opening voltage is greater than 0.58 volt and less than 92°C (197°F),
install a new coolant thermostat. 6. If the coolant thermostat opening voltage is less than 0.58 volt
and greater than 92°C (197°F), the coolant thermostat is good and a new coolant
thermostat should not be installed. GO to Symptom Chart for further instructions.
Thermostat-Mechanical Test
1. Remove the thermostat. 2. Check the thermostat for seating. Hold the thermostat up to a lighted
background. Leakage of light around the thermostat valve at room
temperature indicates that a new thermostat should be installed. Some thermostats have a small
leakage notch at one location on the perimeter of the thermostat valve, which is considered normal.
3. Immerse the thermostat in a boiling antifreeze and water mixture.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Testing and Inspection > Page 3709
Thermostat: Service and Repair
Thermostat and Thermostat Housing
Material
Material
Removal and Installation
1. Drain the engine cooling system. 2. Remove the two bolts, the thermostat housing, and the
thermostat. Discard the O-ring seal.
^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
^ Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Testing and Inspection > Page 3710
^ To install, tighten to 10 Nm (89 inch lbs.).
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair
Thermostat Housing: Service and Repair
Thermostat and Thermostat Housing
Material
Material
Removal and Installation
1. Drain the engine cooling system. 2. Remove the two bolts, the thermostat housing, and the
thermostat. Discard the O-ring seal.
^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
^ Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Page 3714
^ To install, tighten to 10 Nm (89 inch lbs.).
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
TORQUE SPECIFICATIONS
Coolant Pump Bolts .............................................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3718
Water Pump: Service and Repair
Coolant Pump
Material
Material
Removal and Installation
1. Drain the engine cooling system. 2. Remove the cooling fan. 3. Remove the accessory drive
belt. 4. Remove the 4 bolts and the coolant pump pulley.
^ To install, tighten to 25 Nm (18 ft. lbs.).
5. Remove the four bolts and the coolant pump. Discard the O-ring seal.
^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
^ Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation.
^ To install, tighten to 25 Nm (18 ft. lbs.).
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation
Catalytic Converter: Description and Operation
Catalyst and Exhaust Systems Overview
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
carbon dioxide (C02) and water vapor (H20). However~ it also contains carbon monoxide (CO)
oxides of nitrogen (NO) hydrogen (H) and various unburned hydrocarbons (HCs). CO NO 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 front heated
oxygen sensor (HO2S) rear exhaust pipe catalyst HO2S a muffler and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications more than one catalyst will be used between the front and rear exhaust pipes.
Catalytic converter efficiency is monitored by the on-board diagnostic (OBD) system strategy in the
PCM. For information on the OBD catalyst monitor refer to the description for the Catalyst
Efficiency Monitor in this section.
The number of HO2S used in the exhaust stream and the location of these sensors depend on the
vehicle emission certification level (i.e. LEV ULEV PZEV). On most vehicles only 2 HO2S are used
in an exhaust stream. The front sensors (HO2S1 1/H02S21) before the catalyst will be used for
primary fuel control while the ones afier the catalyst (H02S12/H02S22) will be used to monitor
catalyst efficiency. However some partial zero emission vehicles (PZEV) will use 3 HO2S sensors
for each engine bank. The stream 1 sensors (HO2S1 1/H02S21) located before the catalyst are
used for primary fuel control the stream 2 sensors (H02S12/H02S22) are used to monitor the
light-off catalyst and the stream 3 sensors (H02S13/H02S23) located afier the catalyst are used for
long term fuel trim control to optimize catalyst efficiency (fore afi oxygen sensor control). Current
PZEV vehicles use only a 4-cylinder engine so only the Bank 1 HO2S will be used.
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
ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust
gases come in contact with the catalyst they are changed into mostly harmless products. The
catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components
so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up converter efficiency rises rapidly. The point at which conversion efficiency
exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 301°C
(475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the
exhaust
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3723
manifold as possible. Because the light off catalyst is located close to the exhaust manifold it will
light off faster and reduce emissions quicker than the catalyst located under the body. Once the
catalyst lights of{ the catalyst will quickly reach the maximum conversion efficiency for that catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
A TWC requires a stoichiometric fuel ratio 14.7 pounds of air to 1 pound of fuel (14.7: 1) for high
conversion efficiency. In order to achieve these high efficiencies the air/fuel ratio must be tightly
controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly
decrease the conversion efficiency. For example a rich mixture will decrease the HC and CO
conversion efficiency while a lean mixture will decreases the NO conversion efficiency.
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 (NO) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter past
another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally the exhaust
emissions are directed to the atmosphere through an exhaust tailpipe.
Note: On some partial zero emission vehicles (PZEV) there will be a total of 3 HO2S in the exhaust
stream. One near the exhaust manifold (stream 1) one in the middle of the light-off catalyst (stream
2) and the third (stream 3) is mounted afier the light-off catalyst.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3724
Underbody Catalyst
The underbody catalyst is located afier the light off catalyst. The underbody catalyst may be in-line
with the light off catalyst or the underbody catalyst may be common to 2 light off catalysts forming a
Y pipe configuration.
Three-Way Catalytic Converter
The 3-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 NO. The 3-way conversion can be best accomplished by always
operating the engine air fuel/ratio at or close to stoichiometry.
Exhaust Manifold Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Heated Oxygen Sensors (HO2S)
The HO2S provide the powertrain control module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas. For information on the HO2S refer to PCM Inputs
in this section.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine and also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
TORQUE SPECIFICATIONS
LEFT
RIGHT
Exhaust Manifold Bolt ..........................................................................................................................
.................................................... 25 Nm (18 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures
Exhaust Manifold: Service and Repair General Procedures
Exhaust Manifold-Inspection
Special Tools And Equipment
Special Tool(s)
1. Place a straight edge across the exhaust manifold flanges and check for warping with a feeler
gauge.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3730
Exhaust Manifold: Service and Repair Exhaust Manifold
RH
Exhaust Manifold-RH
Special Tools And Equipment
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3731
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the air cleaner housing. 3.
Remove the generator. 4. Remove the starter. 5. Remove the RH inner fenderwell. 6. Remove the
upper radiator shroud.
7. CAUTION: Only use hand tools when loosening the LH engine mount through bolt or damage to
the cage nut can occur.
NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using
service part number W709375. If the LH engine mount through bolt nut cage is damaged or
missing, remove the cage and install a new nut using service part number W520516-S301.
Loosen the LH engine support insulator bolt. ^
To install, tighten to 175 Nm (129 ft. lbs.).
8. CAUTION: Only use hand tools when removing the RH engine mount nut or damage to the
engine mount can occur.
Remove the RH engine mount nut. ^
To install, tighten to 175 Nm (129 ft. lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3732
9. Remove the 4 exhaust manifold-to-catalytic converter nuts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
10. CAUTION: Only use hand tools when removing the transmission mount-to-crossmember nuts
or damage to the transmission mount can occur.
Loosen the 2 transmission mount-to-crossmember nuts. ^
To install, tighten to 103 Nm (76 ft. lbs.).
11. Remove the 4 bolts and position the sway bar down.
^ To install, tighten to 30 Nm (22 ft. lbs.).
12. Install the special tools and raise the engine.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3733
13. Remove the 8 nuts and the exhaust manifold.
^ To install, tighten to 25 Nm (18 ft. lbs.) in the sequence shown.
14. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive
means to clean the sealing surfaces. These may
cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces.
NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface
prep.
15. To install, reverse the removal procedure.
LH
Exhaust Manifold-LH
Special Tools And Equipment
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3734
Removal and Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the air cleaner housing. 3.
Remove the generator. 4. Remove the LH inner fenderwell. 5. Remove the upper radiator shroud.
6. CAUTION: Only use hand tools when removing the LH engine mount through bolt or damage to
the cage nut can occur.
NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using
service part number W709375. If the LH engine mount through bolt nut cage is damaged or
missing, remove the cage and install a new nut using service part number W520516-S301.
Remove the LH engine support insulator bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3735
^ To install, tighten to 175 Nm (129 ft. lbs.).
7. CAUTION: Only use hand tools when loosening the RH engine mount nut or damage to the
engine mount can occur.
Loosen the RH engine mount nut. ^
To install, tighten to 175 Nm (129 ft. lbs.).
8. Remove the 4 exhaust manifold-to-catalytic converter nuts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
9. CAUTION: Only use hand tools when removing the transmission mount-to-crossmember nuts or
damage to the transmission mount can occur.
Loosen the 2 transmission mount-to-crossmember nuts. ^
To install, tighten to 103 Nm (76 ft. lbs.).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > General Procedures > Page 3736
10. Remove the 2 bolts and the exhaust manifold heat shield.
^ To install, tighten to 10 Nm (89 inch lbs.).
4WD vehicles
11. Remove the front driveshaft.
All vehicles
12. Install the special tools and raise the engine.
13. Remove the 8 nuts and the exhaust manifold.
^ To install, tighten to 25 Nm (18 ft. lbs.) in the sequence shown.
14. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive
means to clean the sealing surfaces. These may
cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces.
NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface
prep.
15. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair
Exhaust Pipe: Service and Repair
Dual Converter Y-Pipe
Material
Material
Removal and Installation
CAUTION: Do not use oil or grease-based lubricants on isolators as they deteriorate the rubber.
NOTE: The dual converter Y-pipe is a two-piece assembly. The RH and LH converters can be
serviced separately as needed.
Both RH and LH converters
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the heated oxygen and catalyst monitor sensors.
3. Remove and discard the catalytic converter-to-exhaust manifold nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 3740
4. Loosen the clamp.
LH converter only
5. NOTE: Use caution removing the catalytic converter. Make sure not to damage the manifold
outlet flare, the converter inlet flare or the studs.
Separate and remove the LH converter.
RH converter only
6. Remove and discard the bolts and flag nuts at the RH converter-to-muffler flange. 7. Using a
suitable jack stand, support the muffler.
8. Detach the isolators from the muffler assembly. 9. Lower the muffler assembly.
10. NOTE: Use caution removing the catalytic converter. Make sure not to damage the manifold
outlet flare, the converter inlet flare or the studs.
Remove the bolt, isolator cap and the RH converter.
Both RH and LH converters
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 3741
11. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation.
If necessary, remove the heated oxygen and the catalyst monitor sensors.
12. CAUTION: Do not tighten the fasteners until all components are assembled, making sure to
tighten all fasteners beginning at the front of the
vehicle.
NOTE: Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare.
Also clean the mating surfaces of the inlet pipe and catalytic converter. Make sure not to damage
the manifold outlet flare, the converter inlet flare or the studs.
NOTE: Always install new fasteners and gaskets.
To install, reverse the removal procedure. ^
Align the exhaust system to establish the maximum clearance. Begin at the front of the vehicle. For
torque specifications, refer to Specifications.
^ Tighten all the fasteners in the following order.
^ Tighten the RH lower catalytic converter-to-exhaust manifold nut.
^ Tighten the RH upper catalytic converter-to-exhaust manifold nut.
^ Tighten the transmission mount hanger bolt.
^ Tighten the exhaust clamp nut.
^ Alternately tighten the LH catalytic converter-to-exhaust manifold nuts to avoid an exhaust leak. Install and snug the LH inner nut up.
- Tighten the LH outer nut to specification.
- Tighten the LH inner nut to specification.
^ Tighten the catalytic converter-to-muffler bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair
Heat Shield: Service and Repair
Exhaust Heat Shields
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Inspect the exhaust system for loose or
missing heat shields or foreign material trapped between the heat shields and the exhaust system
components.
3. If any heat shields are loose, install worm gear clamps.
^ Use one of the following clamps: FOTZ-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 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
Muffler and Tailpipe
Removal and Installation
CAUTION: Do not use oil or grease-based lubricants on isolators as they deteriorate the rubber.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Loosen the clamp, separate the isolator from the hanger and remove:
^ An extension pipe for Expedition models.
^ A resonator for Navigator models.
3. Remove the four nuts and two stabilizer bar brackets.
^ Allow the bar to hang from the links.
4. Using a suitable jack stand, support the muffler.
5. Detach the isolators from the muffler.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 3748
6. Remove and discard the bolts and flag nuts.
7. CAUTION: Make sure not to make contact with the axle boots while routing the muffler outlet
over the rear axle or damage to the boots may
result.
Remove the muffler and tailpipe assembly.
8. NOTE: Clean the mating surfaces of the inlet pipe and catalytic converter.
NOTE: Always install new fasteners.
NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations
Body Control Module: Locations
VEHICLE SECURITY MODULE (VSM)
View 151-17 (RH A-Pillar)
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3755
Body Control Module: Diagrams
VEHICLE SECURITY MODULE (VSM)
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3756
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Removal and Installation
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
- Prior to the removal of the module, it is necessary to upload module configuration information to
the appropriate diagnostic equipment. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery.
2. NOTE: The module is accessed with the seat fully in the UP position.
Slide the driver seat module forward to remove it from the bracket.
3. Disconnect the connectors and remove the DSM.
4. CAUTION: Once the module is installed it is necessary to download the module configuration
information from the diagnostic tool into
the new module.
To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM) > Page 3759
Body Control Module: Service and Repair Vehicle Security Module
VEHICLE SECURITY MODULE
Removal
1. NOTE: Prior to removal of the vehicle security module, it is necessary to upload the module
configuration information to a diagnostic tool. This
information needs to be downloaded into the new module once installed.
Disconnect the battery.
2. Remove the pin-type retainer and the RH A-pillar lower trim panel.
3. Disconnect the 3 vehicle security module electrical connectors. 4. Remove the 2 screws and the
vehicle security module.
Installation
1. Position the vehicle security module and install the 2 screws. 2. Connect the 3 vehicle security
module electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type
retainer. 4. Connect the battery. 5. Reconfigure the VSM module. 6. Train the tire pressure
sensors. 7. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The Generation II (Gen II) torque based electronic throttle control (ETC) is a hardware and
software strategy that delivers an engine output torque (via throttle angle) based on driver demand
(pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to
control the throttle opening and engine torque. The ETC system replaces the standard cable
operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and
mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable cam
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: Eliminate cruise control actuators.
- Eliminate idle air control (IAC) valve.
- Better airflow range.
- Packaging (no cable).
- More responsive powertrain at altitude and improved shift quality.
It should be noted that the ETC system includes a warning indicator (wrench light) on the
instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and
may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a
DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The
redundant throttle position signals are required for
increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle,
decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing
voltage). During normal operation the negative slope TP signal (TP1) is used by the control
strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage.
- Signal return (ground).
- TP1 voltage with negative voltage slope (5-0 volts).
- TP2 voltage with positive voltage slope (0-5 volts).
Accelerator Pedal Position (APP) Sensors
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 3763
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts).
- 2 signal return (ground) circuits.
- APP1 voltage with negative voltage slope (5-0 volts).
- APP2 voltage with positive voltage slope (0-5 volts).
- APP3 voltage with positive voltage slope (0-5 volts).
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
fault. The PCM determines if a signal is incorrect
by calculating where it should be, inferred from the other signals. A value will be substituted for an
incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 3764
GEN II ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal
position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 3765
Since the IPC and main controller share the same processor, they are subject to a number of
potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly
monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of
the IPC and the main processor. If it determines that the IPC function is impaired in any way, it
takes appropriate Failure Mode and Effects Management (FMEM) actions.
Electronic Throttle Monitor Operation:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 3766
Electronic Throttle Monitor Operation (Part 1)
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 3767
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position.
- Greater than or equal to 5% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on,
engine off.
- Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard-stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of Range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard-stop.
The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - General PCM Programming Procedures
Engine Control Module: 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 5 (2005))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - General PCM Programming Procedures > Page 3772
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - General PCM Programming Procedures > Page 3773
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
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Page 3774
View 151-1 (Engine Compartment)
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector
Views
Engine Control Module: Connector Views
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The flash electrically erasable programmable read only memory (EEPROM) is contained in an
integrated circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including
calibration information specific to the vehicle, and is capable of being programmed or flashed
repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635
or P1639. The VID block in an existing PCM can also be tailored to accommodate various
hardware or parameter changes made to the vehicle since production. Failure to carry out this
procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An
incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the VIN, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and four wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block will display on the diagnostic tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again
to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other
enhanced diagnostic tools that may have programming capabilities available. Refer to the
manufacturer's user manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and will need programming. There are 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 is carried out if the old PCM is capable of communicating. This is done by
the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle.
The stored data can now be downloaded to the new PCM after it has been installed.
Manual data entry must be Carried out if the old module is damaged or incapable of
communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and
carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make
certain that all parameters are included. Failure to properly program tire size in revolutions per mile,
(rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or
MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built
Data Center for the information needed to manually update the VID block with the diagnostic tool.
Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M
technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for
As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the
Motorcraft homepage, use the search function to find the Module Programming or As Built Data.
For Ford and L-M technicians, check the Programmable Module Installation link on the PTS
website for quick Programmable Module data information by vehicle when using the WDS or New
Generation Star (NGS).
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 3784
Engine Control Module: Service and Repair Removal and Installation
POWERTRAIN CONTROL MODULE (PCM)
Removal and Installation
1. Disconnect the battery ground cable.
2. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
3. Disconnect the powertrain control module (PCM) electrical connectors. 4. Remove the 4 bolts
and the PCM.
- To install, tighten to 7 Nm (62 lb-in).
5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3788
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3789
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3790
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Emission Control Systems > EGR Control Module > Component Information > Description and Operation
EGR Control Module: Description and Operation
EGR SYSTEM MODULE (ESM)
Overview
EGR System Module (ESM)
The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional
DPFE system, however the various system components have been integrated into a single
component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake
manifold with a metal gasket that forms the measuring orifice. This arrangement increases system
reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to
the intake side of the EGR valve, the downstream pressure signal measures manifold absolute
pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a
traditional DPFE system.
The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional
tests that monitor various aspects of the EGR system operation.
First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405
P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403).
NOTE: EGR normally has large amounts of water vapor that are the result of the engine
combustion process. During cold ambient temperatures, under some circumstances, water vapor
can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to
prevent MIL illumination for temporary freezing, the following logic is used.
If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for
the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will
not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines
that the malfunction is no longer present, the EGR system will be enabled and normal system
operation will be restored.
If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor
is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the
malfunction has been detected on 2 consecutive driving cycles.
After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the
low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will
deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is
very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is
evaluated to determine the amount of EGR system restriction. If the differential pressure is below a
calibrated threshold, a low flow malfunction is indicated (P0401/P0406).
Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero
requested EGR flow to carry out the high flow check. If the differential pressure exceeds a
calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR
valve seat (P0402).
If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the
altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run
reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle
leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will
attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is
disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will
be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles
for the EGR monitor to be set to a ready condition.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3799
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3800
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal And Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable.
3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the
fuel tank filler pipe.
Disconnect the fuel pump driver module (FPDM) electrical connector.
4. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 3804
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3808
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3809
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3810
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 3816
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 3817
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-4 (Engine, Front)
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3821
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3822
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3823
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3824
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor 1 > Page 3830
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
3831
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
3832
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
3839
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
3840
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
3841
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
3845
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > CHT Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3848
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3849
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input
Fuel Level Sensor: Description and Operation Fuel Level Input
FUEL LEVEL INPUT
NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in
the tank and the sensor signal is provided as a communications network message by the
instrument cluster to the PCM.
The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP)
module or a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input > Page 3854
Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input > Page 3855
Fuel Level Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input > Page 3856
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Fuel Level Input > Page 3857
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Page 3858
Fuel Level Sensor: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation >
Page 3859
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Rail Pressure (FRP) Sensor
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the pressure decreases. The varying resistance affects the voltage drop across the
sensor terminals and provides electrical signals to the PCM corresponding to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Rail Pressure (FRP) Sensor > Page 3864
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP
leak check monitor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Fuel Tank Pressure (FTP) Sensor > Page 3869
Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Fuel Tank Pressure (FTP) Sensor > Page 3870
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Fuel Tank Pressure (FTP) Sensor > Page 3871
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3872
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect fittings from the fuel
vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect fittings from the fuel
pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the
removal procedure.
- Leak test the system.
- Carry out the evaporative emission repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair
Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
3876
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
3877
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand Alone/Non-integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange
Type MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases
as the temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
3878
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described above. However, one is located before the supercharger at the air cleaner for
standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in
the intake manifold. The IAT2 sensor located after the supercharger provides air temperature
information to the PCM to control border-line spark and to help determine intercooler efficiency.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 >
Page 3884
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3885
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3886
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 3893
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 3894
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 3895
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5.
Remove the EOT sensor. Discard the O-ring seal.
- To install, tighten to 21 Nm (15 lb-ft).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3900
Oxygen Sensor: Harness Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3901
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3902
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3903
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3904
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3905
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 3908
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 3909
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 3910
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3911
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage
according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in
the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the
PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during
closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater
by providing the ground when the proper conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor
(HO2S) electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 3914
3. Using the special tool, remove the HO2S.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 3915
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 3916
3. Using the special tool, remove the catalyst monitor sensor.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch > Page 3921
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
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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 (DPFE) System > Page 3926
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 3927
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set > Page 3936
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL
ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL
ON/DTC's P2106 and P2135 Set > Page 3942
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 3943
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 3944
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3947
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 3948
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 3952
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 3953
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 3954
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 3955
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 3956
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information generated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor > Page 3961
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency
that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity,
the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor
generates a signal with a higher frequency. The PCM uses the frequency signal generated by the
VSS (and other inputs) to control such parameters as fuel injection, ignition control,
transmission/transaxle shift scheduling, and torque converter clutch scheduling.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 3967
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 3968
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 3973
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 3974
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3978
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3979
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3980
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3981
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel
Tank Pressure Transducer Sensor
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel
Tank Pressure Transducer Sensor > Page 3986
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor > Page 3989
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page
3990
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3994
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation > Fuel Rail Pressure Temperature (FRPT) Sensor
Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 3997
Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor
FUEL RAIL TEMPERATURE (FRT) SENSOR
Fuel Rail Temperature (FRT) Sensor
The FRT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation > Page 3998
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4002
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4003
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 IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in
place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a
conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts
off the electric fuel pump. Once the switch is open it must be manually reset before restarting the
vehicle. Refer to the Owner's Literature for the location of the IFS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4004
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3.
Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the two bolts and
the IFS switch.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set > Page 4013
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL
ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL
ON/DTC's P2106 and P2135 Set > Page 4019
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 4020
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Page 4021
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor > Page 4024
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 4025
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
1 > Page 4032
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4033
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4034
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4038
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4039
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4040
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 4046
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 4047
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4053
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4054
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4055
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Description and Operation
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that
relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic
procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and
HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel
Pressure Test Kit #134-R0087 or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
.......................................................... 600 - 650 RPM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
AIR CLEANER INTAKE PIPE
Exploded View
Removal and Installation
1. Remove the air cleaner element.
2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air
cleaner intake pipe to release the air cleaner intake pipe
from the air cleaner assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 4068
3. Remove the air cleaner intake tube assembly.
4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Exploded View
Removal and Installation
1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner
element from the air cleaner element tray.
3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure
to do so will result in unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
Item ......................................................................................................................................................
............................................................ Specification
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System - MIL
ON/DTC P0300-P0308/P0316
Spark Plug: Customer Interest Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System - MIL
ON/DTC P0300-P0308/P0316 > Page 4091
BASIC PART NO. CODE
12405 42
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL
ON/Rough Idle/Long Crank/Misfire/DTC's
Spark Plug: Customer Interest Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
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ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4096
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
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ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4097
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
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ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4098
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-25-4 > Dec > 08 > Ignition
System - MIL ON/DTC P0300-P0308/P0316
Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
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Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-25-4 > Dec > 08 > Ignition
System - MIL ON/DTC P0300-P0308/P0316 > Page 4104
BASIC PART NO. CODE
12405 42
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
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c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
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Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 4111
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
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Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-7-6 > Apr > 08 > Ignition
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Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
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System - Spark Plug Removal Instructions > Page 4113
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
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Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 4114
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
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3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
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4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
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7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
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2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-7-6 > Apr > 08 > Ignition
System - Spark Plug Removal Instructions > Page 4119
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's
Spark Plug: All Technical Service Bulletins Fuel System - MIL ON/Rough Idle/Long
Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4124
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4125
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4126
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 04-26-23 > Dec > 04 >
Steering - Steering Column Creak/Pop/Tick Noise
Steering Shaft: All Technical Service Bulletins Steering - Steering Column Creak/Pop/Tick Noise
TSB 04-26-23
12/31/04
CLUNK, POP, CREAK OR TICK NOISE FROM STEERING COLUMN
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 04-16-14 to update the Service Procedure and affected model years.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 10/18/2004 may exhibit a clunk,
pop, creak, or tick noise coming from the steering column. The noise may occur during
acceleration, deceleration and/or while going over bumps, and is most noticeable after the vehicle
is warmed up. The tick noise may occur when rapidly and repeatedly turning the steering wheel to
the left or right.
ACTION For a clunk, pop or creak condition, it may be necessary to replace the lower intermediate
steering shaft. For a tick condition, inspect the upper-to-lower intermediate shaft union. Refer to the
correct Service Procedure based on symptom.
SERVICE PROCEDURE - Clunk, Pop Or Creak
NOTE
DO NOT ATTEMPT TO ADD GREASE TO THE INTERMEDIATE SHAFT TO RESOLVE THE
CONDITION.
NOTE
BE SURE THE VEHICLE IS AT FULL OPERATING TEMPERATURE DURING VERIFICATION.
1. Road test the vehicle to verify the condition.
2. If condition is verified, replace the lower intermediate steering shaft following the service
procedure in Workshop Manual Section 211-04. Torque the upper-to-lower intermediate shaft bolt
to 40 lb-ft (55 N.m).
NOTE
CHECK BUILD DATE CODES ON THE REPLACEMENT SHAFT PRIOR TO INSTALLATION.
ONLY INSTALL PARTS BUILT AFTER DATE CODE 0410080X (OCTOBER 8, 2004). THE LAST
TWO DIGITS OF THE DATE CODE (0X) INDICATE THE SHIFT IN WHICH THE PARTS WERE
BUILT (X CAN EQUAL 1, 2, OR 3).
SERVICE PROCEDURE - Tick
1. Turn steering wheel rapidly and repeatedly to the left or right while parked to verify the condition.
2. If the condition is verified, inspect the upper-to-lower intermediate shaft union and re-torque the
bolt to 40 lb-ft (55 N.m).
3. If the noise is still present, follow normal diagnostics.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 04-26-23 > Dec > 04 >
Steering - Steering Column Creak/Pop/Tick Noise > Page 4132
Labor Operation Claiming Chart
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3B676 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 04-26-23 > Dec > 04 >
Steering - Steering Column Creak/Pop/Tick Noise > Page 4138
Labor Operation Claiming Chart
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3B676 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap
Spark Plug: Specifications Gap
Spark Plug Gap ...................................................................................................................................
.................................0.040 - 0.50 in (1.02 - 1.27 mm)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap > Page 4141
Spark Plug: Specifications Torque
Spark Plug Torque ...............................................................................................................................
.........................................................34 Nm (25 ft-lb)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 4142
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
.................................................................... PZT-2FE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 PLUGS
Engine Ignition - RH
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Removal and Installation > Page 4145
Engine Ignition - LH
Exploded View
Removal and Installation
1. Remove the ignition coil-on-plug.
2. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Removal and Installation > Page 4146
Spark Plug: Service and Repair Spark Plug-Inspection
Spark Plug-Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or wont or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Service and Repair > Removal and Installation > Page 4147
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a Heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
GENERAL SPECIFICATIONS
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 4151
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 4152
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
GENERAL SPECIFICATIONS
Valves
Valve stem-to-guide clearance - intake
.......................................................................................................................... 0.020-0.045
mm(0.001-0.002 in) Valve stem-to-guide clearance - exhaust
........................................................................................................................ 0.069-0.094
mm(0.003-0.004 in) Valve head diameter intake
............................................................................................................................................
33.62-33.98 mm(1.324-1.338 in) Valve head diameter exhaust
................................................................................................................................... 37.32-37.68
mm(1.469-1.483 in) Valve face runout ................................................................................................
................................................................................ 0.05 mm (0.002 in) Valve face angle ..................
..............................................................................................................................................................
............. 45.5 degrees Valve seat width intake
..........................................................................................................................................................
1.2-1.4 mm (0.047-0.055in) Valve seat width exhaust
........................................................................................................................................................
1.4-1.6 mm (0.055-0.063in) Valve seat angle .....................................................................................
................................................................................................ 44.5-45.0 degrees Valve spring free
length ...................................................................................................................................................
..................... 55.7 mm (2.19 in) Valve spring compression pressure
................................................................................................. 350 N (79 lbs) ± 17.5 N(4 lbs) (a
42.04 mm (1.66in) Valve spring installed height ..................................................................................
............................................................................. 42.04 mm (1.66 in) Valve spring installed
pressure ..................................................................................................... 350 N (79 lbs) ± 17.5 N
(4 lbs) @ 42.04 mm (1.66 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 4160
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 4161
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 4165
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 4166
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 4167
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 4168
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 4172
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 4173
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand Alone/Non-integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange
Type MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases
as the temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 4174
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described above. However, one is located before the supercharger at the air cleaner for
standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in
the intake manifold. The IAT2 sensor located after the supercharger provides air temperature
information to the PCM to control border-line spark and to help determine intercooler efficiency.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations
Body Control Module: Locations
VEHICLE SECURITY MODULE (VSM)
View 151-17 (RH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 4178
Body Control Module: Diagrams
VEHICLE SECURITY MODULE (VSM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Page 4179
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Removal and Installation
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
- Prior to the removal of the module, it is necessary to upload module configuration information to
the appropriate diagnostic equipment. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery.
2. NOTE: The module is accessed with the seat fully in the UP position.
Slide the driver seat module forward to remove it from the bracket.
3. Disconnect the connectors and remove the DSM.
4. CAUTION: Once the module is installed it is necessary to download the module configuration
information from the diagnostic tool into
the new module.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM) > Page 4182
Body Control Module: Service and Repair Vehicle Security Module
VEHICLE SECURITY MODULE
Removal
1. NOTE: Prior to removal of the vehicle security module, it is necessary to upload the module
configuration information to a diagnostic tool. This
information needs to be downloaded into the new module once installed.
Disconnect the battery.
2. Remove the pin-type retainer and the RH A-pillar lower trim panel.
3. Disconnect the 3 vehicle security module electrical connectors. 4. Remove the 2 screws and the
vehicle security module.
Installation
1. Position the vehicle security module and install the 2 screws. 2. Connect the 3 vehicle security
module electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type
retainer. 4. Connect the battery. 5. Reconfigure the VSM module. 6. Train the tire pressure
sensors. 7. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 4186
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 4189
Brake Signal: Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch
BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH
The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control
deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the
brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens
and power is removed from the PCM.
On some applications the normally closed BPS, along with the normally open brake pedal position
(BPP) switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile
learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to
the PCM did not change states when they were expected to, a diagnostic trouble code P1572 can
be set by the PCM strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4195
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 4196
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 4197
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 4204
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 4205
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 4206
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 4215
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The Generation II (Gen II) torque based electronic throttle control (ETC) is a hardware and
software strategy that delivers an engine output torque (via throttle angle) based on driver demand
(pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to
control the throttle opening and engine torque. The ETC system replaces the standard cable
operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and
mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable cam
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: Eliminate cruise control actuators.
- Eliminate idle air control (IAC) valve.
- Better airflow range.
- Packaging (no cable).
- More responsive powertrain at altitude and improved shift quality.
It should be noted that the ETC system includes a warning indicator (wrench light) on the
instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and
may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a
DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The
redundant throttle position signals are required for
increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle,
decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing
voltage). During normal operation the negative slope TP signal (TP1) is used by the control
strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage.
- Signal return (ground).
- TP1 voltage with negative voltage slope (5-0 volts).
- TP2 voltage with positive voltage slope (0-5 volts).
Accelerator Pedal Position (APP) Sensors
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 4219
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts).
- 2 signal return (ground) circuits.
- APP1 voltage with negative voltage slope (5-0 volts).
- APP2 voltage with positive voltage slope (0-5 volts).
- APP3 voltage with positive voltage slope (0-5 volts).
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
fault. The PCM determines if a signal is incorrect
by calculating where it should be, inferred from the other signals. A value will be substituted for an
incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 4220
GEN II ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal
position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 4221
Since the IPC and main controller share the same processor, they are subject to a number of
potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly
monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of
the IPC and the main processor. If it determines that the IPC function is impaired in any way, it
takes appropriate Failure Mode and Effects Management (FMEM) actions.
Electronic Throttle Monitor Operation:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 4222
Electronic Throttle Monitor Operation (Part 1)
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 4223
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position.
- Greater than or equal to 5% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on,
engine off.
- Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard-stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of Range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard-stop.
The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures
Engine Control Module: 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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page
4228
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
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
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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
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 4230
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views
Engine Control Module: Connector Views
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views > Page 4233
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Component Information > Diagrams > Connector Views > Page 4234
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views > Page 4235
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views > Page 4236
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views > Page 4237
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The flash electrically erasable programmable read only memory (EEPROM) is contained in an
integrated circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including
calibration information specific to the vehicle, and is capable of being programmed or flashed
repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635
or P1639. The VID block in an existing PCM can also be tailored to accommodate various
hardware or parameter changes made to the vehicle since production. Failure to carry out this
procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An
incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the VIN, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and four wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block will display on the diagnostic tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again
to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other
enhanced diagnostic tools that may have programming capabilities available. Refer to the
manufacturer's user manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and will need programming. There are 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 is carried out if the old PCM is capable of communicating. This is done by
the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle.
The stored data can now be downloaded to the new PCM after it has been installed.
Manual data entry must be Carried out if the old module is damaged or incapable of
communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and
carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make
certain that all parameters are included. Failure to properly program tire size in revolutions per mile,
(rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or
MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built
Data Center for the information needed to manually update the VID block with the diagnostic tool.
Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M
technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for
As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the
Motorcraft homepage, use the search function to find the Module Programming or As Built Data.
For Ford and L-M technicians, check the Programmable Module Installation link on the PTS
website for quick Programmable Module data information by vehicle when using the WDS or New
Generation Star (NGS).
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) >
Page 4240
Engine Control Module: Service and Repair Removal and Installation
POWERTRAIN CONTROL MODULE (PCM)
Removal and Installation
1. Disconnect the battery ground cable.
2. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
3. Disconnect the powertrain control module (PCM) electrical connectors. 4. Remove the 4 bolts
and the PCM.
- To install, tighten to 7 Nm (62 lb-in).
5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations
View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 4244
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > CHT Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > CHT Sensor > Page 4247
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > Page 4248
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Fuel Level Input
Fuel Level Sensor: Description and Operation Fuel Level Input
FUEL LEVEL INPUT
NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in
the tank and the sensor signal is provided as a communications network message by the
instrument cluster to the PCM.
The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP)
module or a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Fuel Level Input > Page 4253
Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Fuel Level Input > Page 4254
Fuel Level Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Fuel Level Input > Page 4255
Mechanical Returnless Fuel Pump Module (FPM)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Fuel Level Input > Page 4256
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Page 4257
Fuel Level Sensor: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
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Information > Description and Operation > Page 4258
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor >
Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the pressure decreases. The varying resistance affects the voltage drop across the
sensor terminals and provides electrical signals to the PCM corresponding to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor >
Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 4263
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component
Information > Description and Operation
Fuel Pump Signal: Description and Operation
Fuel Pump Monitor (FPM)
Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control
The FPM circuit is spliced into the fuel pump power (FP PWR) circuit and is used by the PCM for
diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel
pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump
off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are
complete from the FPM splice through the fuel pump to ground. This also confirms that the FP
PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage is now being
supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel pump on and the
FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump relay to the FPM
splice is complete. It can also verify that the fuel pump relay contacts are closed and there is a B+
supply to the fuel pump relay.
Fuel Pump Driver Module (FPDM) Applications
Fuel Pump Driver Module Duty Cycle Signals
NOTE: The Ford GT uses 2 FPDMs to control fuel for the dual-injection fuel delivery system. The
PCM will individually monitor both FPDMs through their FPM circuits.
The FPDM communicates diagnostic information to the PCM through the FPM circuit. This
information is sent by the FPDM as a duty cycle signal. The 3 duty cycle signals that may be sent
are listed in the table.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP
leak check monitor.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Fuel Tank Pressure (FTP) Sensor > Page 4271
Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Fuel Tank Pressure (FTP) Sensor > Page 4272
Mechanical Returnless Fuel Pump Module (FPM)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Fuel Tank Pressure (FTP) Sensor > Page 4273
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Page 4274
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect fittings from the fuel
vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect fittings from the fuel
pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the
removal procedure.
- Leak test the system.
- Carry out the evaporative emission repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair
Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation
Idle Speed/Throttle Actuator - Electronic: Description and Operation
IDLE AIR CONTROL (IAC) VALVE (APPLICATIONS WITHOUT ETC)
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
NOTE: The IAC valve assembly is NOT ADJUSTABLE and CANNOT BE CLEANED, also some
IAC valves are normally open and others are normally closed. Some IAC valves require engine
vacuum to operate.
The PCM uses the IAC valve assembly to control:
- No touch start.
- Cold engine fast idle for rapid warm-up.
- Idle (corrects for engine load).
- Stumble or stalling on deceleration (provides a dashpot function).
- Over-temperature idle boost.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Information > Diagrams > Diagram Information and Instructions > Page 4282
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
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Symbols and Wire Color Code Identification
Symbols Part 1
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Symbols Part 2
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Symbols Part 3
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Symbols Part 4
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Symbols Part 5
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Information Bus: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
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3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
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Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
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Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
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Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Information Bus: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
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Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
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Information Bus: Description and Operation
COMMUNICATIONS NETWORK
The communications network consists of the following components:
- air suspension control module
- anti-lock brake system (ABS) module
- climate controlled seat module
- data link connector (DLC)
- driver seat module (DSM)
- dual automatic temperature control (DATC) module
- instrument cluster
- navigation system module
- parking aid module
- powertrain control module (PCM)
- power liftgate module
- restraint control module (RCM)
- transmission control module (TCM)
- vehicle security module
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Information Bus: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
VISUAL INSPECTION CHART
Electrical Central junction box (CJB) fuse 41 (20A)
- Wiring harness
- Connections
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the cause is not visually evident, connect the diagnostic
tool to the data link connector (DLC) and select the vehicle to be tested from the
diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: Check that the program card is correctly installed.
- Check the connections to the vehicle.
- Check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. GO to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck)
Principles of Operation
PRINCIPLES OF OPERATION
The vehicle has 4 module communications networks:
- the standard corporate protocol (SCP) communications network (Navigator with navigation
system only)
- the international standards organization (ISO) 9141 communications network
- the medium speed controller area network (CAN)
- the high speed CAN
The diagnostic tool connects to all 4 networks through the data link connector (DLC). This makes
diagnosis and testing of these systems easier by allowing one diagnostic tester to be able to
diagnose and control any module on the 4 networks from one connector. The DLC can be found
under the instrument panel between the steering column and the audio unit.
The SCP communications network (Navigator with navigation system only) remains operational
even with the severing of one of the SCP communications network circuits. Communications also
continue if one of the SCP communications network circuits are shorted to ground or voltage, or if
some but not all termination resistors are lost. The SCP communications network allows
inter-module communication.
The ISO 9141 communications network is a single circuit communications network, circuit 70
(LB/WH). The ISO 9141 communications network does not permit intermodule communication.
When the diagnostic tool communicates to modules on the ISO 9141 communications network, the
diagnostic tool must request all information, or initiate module commands. The ISO 9141
communications network does not function if the circuit is shorted to ground or battery voltage.
Also, if one of the modules on the ISO 9141 communications network loses power or shorts
internally, communications to that module fail.
The high speed CAN has an unshielded twisted pair cable, data plus circuit 1814 (WH/LB) and
data minus circuit 1815 (PK/LB). The high speed CAN is a high speed communications network
used for the anti-lock brake system (ABS) module, the instrument cluster, the transmission control
module (TCM) and the powertrain control module (PCM) communication. The high speed CAN
remains operational even with the severing of one of the high speed CAN circuits. Communications
also continues if one of the high speed CAN circuits are shorted to ground or voltage, or if some,
but not all, termination resistors are lost.
The medium speed CAN has an unshielded twisted pair cable, data plus circuit 2180 (WH/BK) and
data minus, circuit 2181 (BK/YE). The medium speed CAN is used for the air suspension control
module, the climate controlled seat module, the driver seat module (DSM), the dual automatic
temperature control (DATC) module, the instrument cluster, the parking aid module, power liftgate
module, and the vehicle security module communications. The medium speed CAN remains
operational even with the severing of one of the medium speed CAN circuits. Communications also
continues if one of the medium speed CAN circuits are shorted to ground or voltage, or if some, but
not all, termination resistors are lost.
Air Suspension Control Module
The air suspension control module uses the medium speed CAN. The air suspension control
module controls the air compressor motor (through a solid state relay) and all system solenoids.
The module also provides power to front and rear height sensors on 4-wheel air suspension
systems, or rear height sensors on the rear-wheel suspension systems. The module controls
vehicle height adjustments by monitoring 2 height sensors, vehicle speed, a
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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.
ABS Module
The ABS module uses the high speed CAN. The ABS module controls the brake pressure to the 4
wheels to keep the vehicle under control while braking.
Climate Controlled Seat Module
The climate controlled seat module uses the medium speed CAN. The climate controlled seat
module control the temperature of the driver and passenger seats.
DSM
The DSM uses the medium speed CAN. The DSM controls the positioning and programming of the
driver seat, pedals and both outside mirrors.
DATC Module
The DATC module uses the medium speed CAN. The DATC module controls automatic climate
functions that maintain the vehicle interior temperature at a constant setting.
Instrument Cluster
The instrument cluster uses the medium speed CAN. The instrument cluster also uses the high
speed CAN to communicate with other modules. It is an analog face cluster with a digital odometer.
The instrument cluster displays a variety of information.
Navigation System Module
The navigation module is on the SCP communications network (Navigator only). The navigation
system module controls the global positioning system on the vehicle.
Parking Aid Module
The parking aid module uses the ISO 9141 communications network (Expedition only), or the
medium speed CAN (Navigator only). The module controls sensors in the rear bumper that detect
close objects when the transmission is in REVERSE.
PCM
The PCM uses the high speed CAN. The PCM controls the engine for better fuel economy,
emissions control, failure mode detection and storage. The PCM also controls 4x4 functionality.
Power Liftgate Module
The power liftgate module uses the medium speed CAN (Navigator only). The module controls the
motor that opens and closes the liftgate. Restraints Control Module (RCM) The RCM uses the ISO
9141 communications network. The RCM controls the deployment of the air bags based on sensor
input.
TCM
The TCM uses the high speed CAN (Navigator only). The TCM controls transaxle shifting, the
electronic pressure control, and the torque converter clutch.
Vehicle Security Module
The vehicle security module uses the medium speed CAN. The vehicle security module controls a
variety of systems: exterior lamps
- interior lamps
- lock functions
- monitors the entry doors and radio
- perimeter security
- power windows
- remote keyless entry (RKE)/keyless entry
- tire pressure monitoring system
- warning chimes
- windshield wipers
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U0073-U1900
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Information Bus: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
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Symptom Chart (Part 2)
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Symptom Chart (Part 3)
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Information Bus: Pinpoint Tests
Pinpoint Test PC (Precheck)
PINPOINT TEST PC: DATA LINK DIAGNOSTICS NETWORK TEST
PC1
Test A: The Anti-Lock Brake System (ABS) Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST A: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND
TO THE DIAGNOSTIC TOOL
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A1-A2
A2-A3
Test B: The Restraint Control Module (RCM) Does Not Respond to the Diagnostic Tool
PINPOINT TEST B: THE RESTRAINT CONTROL MODULE (RCM) DOES NOT RESPOND TO
THE DIAGNOSTIC TOOL
B1
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B2-B3
Test C: The Vehicle Security Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST C: THE VEHICLE SECURITY MODULE DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
C1
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C2-C3
Test D: The Powertrain Control Module (PCM) Does Not Respond to the Diagnostic Tool
PINPOINT TEST D: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO
THE DIAGNOSTIC TOOL
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D1-D3
Test E: The Dual Automatic Temperature Control (DATC) Module Does Not Respond to the
Diagnostic Tool
PINPOINT TEST E: THE DUAL AUTOMATIC TEMPERATURE CONTROL (DATC) MODULE
DOES NOT RESPOND TO THE DIAGNOSTIC TOOL
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E1-E3
Test F: The Driver Seat Module (DSM) Does Not Respond to the Diagnostic Tool
PINPOINT TEST F: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
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F1-F3
Test G: The Parking Aid Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST G: THE PARKING AID MODULE DOES NOT RESPOND TO THE DIAGNOSTIC
TOOL
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G1-G3
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G3-G4
Test H: The Transmission Control Module (TCM) Does Not Respond to the Diagnostic Tool
PINPOINT TEST H: THE TRANSMISSION CONTROL MODULE (TCM) DOES NOT RESPOND
TO THE DIAGNOSTIC TOOL
H1
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H2-H3
Test I: The Instrument Cluster Does Not Respond to the Diagnostic Tool
PINPOINT TEST I: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE DIAGNOSTIC
TOOL
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I1-I2
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I3-I4
Test J: The Power Liftgate Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST J: THE POWER LIFTGATE MODULE DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
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J1-J3
Test K: The Air Suspension Control Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST K: THE AIR SUSPENSION CONTROL MODULE DOES NOT RESPOND TO
THE DIAGNOSTIC TOOL
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K1-K2
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K3
Test L: The Climate Controlled Seat Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST L: THE CLIMATE CONTROLLED SEAT MODULE DOES NOT RESPOND TO
THE DIAGNOSTIC TOOL
L1-L2
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4330
L2-L3
Test M: The Navigation System Module Does Not Respond to the Diagnostic Tool
PINPOINT TEST M: THE NAVIGATION SYSTEM MODULE DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
M1-M2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4331
M3-M4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4332
M4-M5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
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M6
Test N: No International Standards Organization (ISO) 9141 Communications Network
Communication
PINPOINT TEST N: NO INTERNATIONAL STANDARDS ORGANIZATION (ISO) 9141
COMMUNICATIONS NETWORK COMMUNICATION
N1-N3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4334
N3-N6
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4335
N7
Test O: No High Speed Controller Area Network (CAN) Communication
PINPOINT TEST O: NO HIGH SPEED CONTROLLER AREA NETWORK (CAN)
COMMUNICATION
O1-O3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4336
O3-O4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4337
O4-O5
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4338
O6-O7
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4339
O8-O12
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4340
O13-O15
Test P: No Medium Speed Controller Area Network (CAN) Communication
PINPOINT TEST P: NO MEDIUM SPEED CONTROLLER AREA NETWORK (CAN)
COMMUNICATION
P1-P2
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P3
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P4-P5
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P5-P6
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P6-P7
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P8
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P9
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P10-P11
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P12-P14
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P15-P19
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P20-P23
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4351
P24-P27
Test Q: No Module/Network Communication - No Power to the Diagnostic Tool
PINPOINT TEST Q: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE
DIAGNOSTIC TOOL
Q1
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Q2-Q4
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4353
Information Bus: Component Tests and General Diagnostics
Principles of Operation
PRINCIPLES OF OPERATION
Definition of Terms
Calibration update: Some modules are designed to be flashed or reflashed with complete new
software packages. This process of reflashing the module is a calibration update.
Programmable parameters: These are options contained within the existing software. These
include items such as tire size, customer preference items and anti-theft options. The current
settings are downloaded from an existing module then uploaded to a new module. They can also
be configured using the diagnostic tool. Programming the parameters is different from updating
calibrations as no software is changed, only the options already contained in the software.
Some modules must be programmed as part of the repair procedure. If this procedure is not
followed the module does not function correctly and may set a number of diagnostic trouble codes
(DTCs), including B2477 or P1639, which indicate that some necessary data has not been
programmed into the module.
Modules that need programming should not be exchanged between vehicles. In most cases the
parameter values or settings are unique to that vehicle, and if not set correctly cause concerns or
faults.
The WDS automatically attempts to retrieve the module configuration information from all modules.
If the module does not contain correct information, the diagnostic tool either requests As Built data
or displays a list of items needed to manually configure the module. The diagnostic tool programs
the module based on the data entered.
For additional WDS/diagnostic tool programming procedures, refer to Programmable Module
Installation.
There are 3 different methods that are used for module programming:
- programmable module installation (PMI)
- calibration update
- programmable parameters
Some modules do not support all 3 methods.
PMI The PMI method is used when a new programmable module is installed on the vehicle. It is no
longer necessary to command the diagnostic tool to gather module option content from the old
module. The diagnostic tool automatically obtains any available module option content information
from the old module during the vehicle ID routine that runs when the diagnostic tool is initially
connected to the vehicle. It is important that you connect the WDS to the vehicle and allow it to
identify the vehicle and obtain configuration data prior to removing any modules.
Calibration Update Calibration update is used to install a new calibration and strategy into a
module.
Programmable Parameters If a module that has been modified using programmable parameters
needs to be installed, the PMI procedure maintains the parameters in their altered state if the WDS
is able to communicate with the old module during vehicle ID. Otherwise, it may be necessary to
use programmable parameters to return the parameters to the altered state.
Vehicle Identification (VID) Block
Some powertrain control modules (PCMs) contain a memory area called a VID block.
The PCM VID block may contain the factory settings for the configurable modules unless the PCM
is flashed with a new calibration, in which case some PCM parameters may be modified.
As-Built Data Center
The As-Built Data Center maintains a record of the vehicle configuration in a database. The vehicle
identification number (VIN) is required to obtain this information. The As-Built Data Center records
the applicable module configurations stored in each module before the vehicle leaves the factory.
The As-Built Data Center always reflects the original build of the vehicle as it left the factory. Only
contact the As-Built Data Center when directed to do so by the diagnostic tool.
Inspection and Verification
INSPECTION AND VERIFICATION
1. Visually inspect for obvious signs of electrical damage.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4354
VISUAL INSPECTION CHART
Electrical Wiring harness
- Connectors
Configurable Modules
The vehicle contains the following modules that are configurable: anti-lock brake system (ABS) module
- driver seat module (DSM)
- dual automatic temperature control (DATC) module
- instrument cluster
- navigation system module
- powertrain control module (PCM)
- power liftgate module
- temperature-controlled seat module
- vehicle dynamics module
- vehicle security module
Programmable Parameter Index
Programmable Parameters Index
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
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Information Bus: Service and Repair
PROGRAMMABLE MODULE INSTALLATION
Worldwide Diagnostic System (WDS)
Special Tool(s)
Using the Vehicle Communication Module (VCM) When the Original Module is Not Available
1. Install the new module. 2. Using the VCM and the latest version of the service function card,
SELECT: Programmable Module Installation. 3. Select the module being installed. 4. Follow the
on-screen instructions. 5. SELECT: Retrieve Module Configuration - Old ECU and press trigger. 6.
Follow the on-screen instructions. 7. The VCM attempts to retrieve the module data.
- If the module data is available, go to Step A.
- If the VCM displays: Call the As-Built Data Center, go to Step B.
Step A 1. SELECT: Restore Configuration - New ECU. Press trigger. 2. The VCM completes
loading the retrieved data and displays Module Download Successful. 3. Test the module for
correct operation.
Step B 1. Press the trigger. 2. If the VCM asks for vehicle data, enter the vehicle data, then press
store. 3. The VCM asks for module data line 1. Enter the data and press store. 4. The VCM then
asks if there is an additional line of data available for that address. Select YES or NO depending on
the information in the As Built
Data Sheet.
5. Repeat Steps 3 and 4 until the answer is NO for Step 4. 6. The VCM should show a screen
stating that the module data was stored. Press the trigger. 7. Follow the on-screen instructions. 8.
SELECT: Restore Configuration - New ECU. Press the trigger. 9. The VCM completes loading the
retrieved data and displays Module Download Successful.
10. Test the module for correct operation.
Using the Vehicle Communication Module (VCM) When the Original Module is Available
1. With the original module still installed, using the VCM and the latest version of the service
function card, SELECT: Programmable Module
Installation.
2. Select the module being installed and press the trigger. 3. Follow the on-screen instructions. 4.
SELECT: Retrieve Module Configuration - Old ECU. Press the trigger. 5. Follow the on-screen
instructions. 6. INSTALL new module, SELECT: Restore Configuration - New ECU. Press the
trigger. 7. The VCM completes loading the retrieved data and displays Module Download
Successful. 8. Test the module for correct operation.
Using the Worldwide Diagnostic System (WDS) When the Original Module is Not Available
1. Install the new module. 2. Connect the WDS and ID the vehicle as normal. 3. From the Toolbox
icon, select and highlight Module Programming. Then highlight the module that was installed and
press the check mark. 4. Select and highlight Programmable Module Installation. Then highlight the
module that was installed and press the check mark. 5. Follow the on-screen instructions, turn the
ignition key to the RUN position and press the check mark. 6. The WDS retrieves the module data,
automatically downloads the data into the new module, and displays Module Configuration
Complete. 7. If the data is not available in the module, the WDS displays a screen stating to
contact the As-Built Data Center. Retrieve the data from
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WWW.FMCDEALER.COM at this time and press the check mark.
8. Enter the module data (the module address and line are displayed to the left of the 3 entry
boxes) and press the check mark. 9. The WDS downloads the data into the new module and
displays Operation Successful - Programming Complete.
10. Test the module for correct operation.
Using the Worldwide Diagnostic System (WDS) When the Original Module is Available
1. Connect the WDS and ID the vehicle as normal. 2. From the Toolbox icon, select and highlight
Module Programming and press the check mark. 3. Select and highlight Programmable Module
Installation. 4. Follow the on-screen instructions, turn the ignition key to the OFF position, and
press the check mark. 5. Install the new module and press the check mark. 6. Follow the on-screen
instructions, turn the ignition key to the ON position, and press the check mark. 7. The module
configuration is complete. 8. Test the module for correct operation.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
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Information Bus: Tools and Equipment
Special Tool(s)
Worldwide Diagnostic System (WDS)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Knock Sensor 1
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Knock Sensor 1 > Page 4363
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 4364
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
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Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4369
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4370
Main Relay (Computer/Fuel System): Testing and Inspection
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System) > Component Information > Locations > Page 4371
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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)
The MIL notifies the driver that the powertrain control module (PCM) has detected an OBD
emission-related component or system fault. When this occurs an OBD diagnostic trouble code
(DTC) will be set.
^ The MW is located in the instrument cluster and is labeled CHECK ENGINE SERVICE ENGINE
SOON or the ISO standard engine symbol.
^ The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
^ For applications with a dedicated hard wire MIL circuit the PCM will illuminate the MIL until a
profile ignition pickup (PIP) signal is detected. For 2OO5 the following vehicles use a hard wire
circuit: Crown Victoria/Grand Marquis Explorer Sport Trac and Ranger.
^ The MIL will remain illuminated after instrument cluster prove out if:
^ an emission related concern and DTC exists.
^ no PIP signal is detected (applications with a dedicated hard-wire MIL circuit). The PIP signal is
generated in the PCM using the crankshafi position (CKP) sensor. For these applications the MIL
can be helpful in diagnosing a no start.
^ the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
^ the PCM is operating in the Hardware Limited Operation Strategy (KLOS).
^ the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit).
^ The MIL remains off during the instrument cluster prove out if:
^ an indicator or instrument cluster concern is present.
^ the MIL circuit is open (applications with a dedicated hard wire MIL circuit).
^ To turn off the MIL afier a repair a reset command from the diagnostic tool must be sent or 3
consecutive drive cycles must be completed without a fault.
^ For all MIL concerns go to Symptom Charts.
^ If the MIL flashes at a steady rate a severe misfire condition may exist.
^ If the MIL flashes erratically the PCM can reset while cranking if the battery voltage is low.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations
View 151-4 (Engine, Front)
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> Component Information > Locations > Page 4381
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 4382
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 4383
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5.
Remove the EOT sensor. Discard the O-ring seal.
- To install, tighten to 21 Nm (15 lb-ft).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Information > Locations > Component Locations > Page 4388
Oxygen Sensor: Harness Locations
View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations > Page 4389
View 151-7 (Transmission - 4R75E)
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Information > Locations > Component Locations > Page 4390
View 151-9 Transmission - 6HP26 Automatic
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Information > Locations > Component Locations > Page 4391
View 151-4 (Engine, Front)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations > Page 4392
View 151-7 (Transmission - 4R75E)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations > Page 4393
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4396
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4397
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Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4398
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Information > Diagrams > Page 4399
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage
according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in
the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the
PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during
closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater
by providing the ground when the proper conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor
(HO2S) electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4402
3. Using the special tool, remove the HO2S.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4403
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4404
3. Using the special tool, remove the catalyst monitor sensor.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 4409
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR (DPFE) System
> Page 4414
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR (DPFE) System
> Page 4415
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Locations
Body Control Module: Locations
VEHICLE SECURITY MODULE (VSM)
View 151-17 (RH A-Pillar)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Locations > Page 4420
Body Control Module: Diagrams
VEHICLE SECURITY MODULE (VSM)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Locations > Page 4421
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Removal and Installation
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
- Prior to the removal of the module, it is necessary to upload module configuration information to
the appropriate diagnostic equipment. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery.
2. NOTE: The module is accessed with the seat fully in the UP position.
Slide the driver seat module forward to remove it from the bracket.
3. Disconnect the connectors and remove the DSM.
4. CAUTION: Once the module is installed it is necessary to download the module configuration
information from the diagnostic tool into
the new module.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) >
Page 4424
Body Control Module: Service and Repair Vehicle Security Module
VEHICLE SECURITY MODULE
Removal
1. NOTE: Prior to removal of the vehicle security module, it is necessary to upload the module
configuration information to a diagnostic tool. This
information needs to be downloaded into the new module once installed.
Disconnect the battery.
2. Remove the pin-type retainer and the RH A-pillar lower trim panel.
3. Disconnect the 3 vehicle security module electrical connectors. 4. Remove the 2 screws and the
vehicle security module.
Installation
1. Position the vehicle security module and install the 2 screws. 2. Connect the 3 vehicle security
module electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type
retainer. 4. Connect the battery. 5. Reconfigure the VSM module. 6. Train the tire pressure
sensors. 7. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The Generation II (Gen II) torque based electronic throttle control (ETC) is a hardware and
software strategy that delivers an engine output torque (via throttle angle) based on driver demand
(pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to
control the throttle opening and engine torque. The ETC system replaces the standard cable
operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and
mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable cam
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: Eliminate cruise control actuators.
- Eliminate idle air control (IAC) valve.
- Better airflow range.
- Packaging (no cable).
- More responsive powertrain at altitude and improved shift quality.
It should be noted that the ETC system includes a warning indicator (wrench light) on the
instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and
may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a
DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The
redundant throttle position signals are required for
increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle,
decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing
voltage). During normal operation the negative slope TP signal (TP1) is used by the control
strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage.
- Signal return (ground).
- TP1 voltage with negative voltage slope (5-0 volts).
- TP2 voltage with positive voltage slope (0-5 volts).
Accelerator Pedal Position (APP) Sensors
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
4428
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts).
- 2 signal return (ground) circuits.
- APP1 voltage with negative voltage slope (5-0 volts).
- APP2 voltage with positive voltage slope (0-5 volts).
- APP3 voltage with positive voltage slope (0-5 volts).
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
fault. The PCM determines if a signal is incorrect
by calculating where it should be, inferred from the other signals. A value will be substituted for an
incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
4429
GEN II ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal
position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
4430
Since the IPC and main controller share the same processor, they are subject to a number of
potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly
monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of
the IPC and the main processor. If it determines that the IPC function is impaired in any way, it
takes appropriate Failure Mode and Effects Management (FMEM) actions.
Electronic Throttle Monitor Operation:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
4431
Electronic Throttle Monitor Operation (Part 1)
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
4432
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position.
- Greater than or equal to 5% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on,
engine off.
- Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard-stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of Range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard-stop.
The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures
Engine Control Module: 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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4437
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
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4438
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4439
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views
Engine Control Module: Connector Views
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4442
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4443
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4444
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4445
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4446
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable
Programmable Read Only Memory (EEPROM)
Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The flash electrically erasable programmable read only memory (EEPROM) is contained in an
integrated circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including
calibration information specific to the vehicle, and is capable of being programmed or flashed
repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635
or P1639. The VID block in an existing PCM can also be tailored to accommodate various
hardware or parameter changes made to the vehicle since production. Failure to carry out this
procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An
incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the VIN, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and four wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block will display on the diagnostic tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again
to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other
enhanced diagnostic tools that may have programming capabilities available. Refer to the
manufacturer's user manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and will need programming. There are 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 is carried out if the old PCM is capable of communicating. This is done by
the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle.
The stored data can now be downloaded to the new PCM after it has been installed.
Manual data entry must be Carried out if the old module is damaged or incapable of
communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and
carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make
certain that all parameters are included. Failure to properly program tire size in revolutions per mile,
(rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or
MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built
Data Center for the information needed to manually update the VID block with the diagnostic tool.
Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M
technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for
As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the
Motorcraft homepage, use the search function to find the Module Programming or As Built Data.
For Ford and L-M technicians, check the Programmable Module Installation link on the PTS
website for quick Programmable Module data information by vehicle when using the WDS or New
Generation Star (NGS).
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable
Programmable Read Only Memory (EEPROM) > Page 4449
Engine Control Module: Service and Repair Removal and Installation
POWERTRAIN CONTROL MODULE (PCM)
Removal and Installation
1. Disconnect the battery ground cable.
2. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
3. Disconnect the powertrain control module (PCM) electrical connectors. 4. Remove the 4 bolts
and the PCM.
- To install, tighten to 7 Nm (62 lb-in).
5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4453
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4454
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4455
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4460
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4461
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-4 (Engine, Front)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4465
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4466
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4467
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4468
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor 1 > Page 4474
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4475
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4476
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4483
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4484
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4485
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 4489
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation >
CHT Sensor
Engine Temperature Sensor: Description and Operation CHT Sensor
The CHT sensor:
^ is mounted into the wall of the cylinder head and is not connected to any coolant passages.
^ sends the PCM a signal indicating cylinder head temperature.
^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel
injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles.
The cylinders that are not being fuel injected act as air pumps to aid in engine cooling.
^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel
injectors until the engine temperature drops below approximately 1 54°C (31 0°F).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 4492
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
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 CHT sensor is installed in the aluminum cylinder head and measures the metal temperature.
The CHT sensor can provide complete engine temperature information and can be used to infer
coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM
would then initiate a fail-safe 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 both the CHT sensor and fail-safe
cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home
capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling
Strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 4493
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper
harness electrical connector. 3. Remove and discard the CHT sensor.
- To install, tighten to 10 Nm (89 lb-in).
- Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Level
Input
Fuel Level Sensor: Description and Operation Fuel Level Input
FUEL LEVEL INPUT
NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in
the tank and the sensor signal is provided as a communications network message by the
instrument cluster to the PCM.
The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP)
module or a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Level
Input > Page 4498
Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Level
Input > Page 4499
Fuel Level Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Level
Input > Page 4500
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Level
Input > Page 4501
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4502
Fuel Level Sensor: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4503
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Rail
Pressure (FRP) Sensor
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the pressure decreases. The varying resistance affects the voltage drop across the
sensor terminals and provides electrical signals to the PCM corresponding to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Rail
Pressure (FRP) Sensor > Page 4508
Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation >
Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP
leak check monitor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation >
Fuel Tank Pressure (FTP) Sensor > Page 4513
Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation >
Fuel Tank Pressure (FTP) Sensor > Page 4514
Mechanical Returnless Fuel Pump Module (FPM)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation >
Fuel Tank Pressure (FTP) Sensor > Page 4515
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 4516
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect fittings from the fuel
vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect fittings from the fuel
pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the
removal procedure.
- Leak test the system.
- Carry out the evaporative emission repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair
Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4520
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4521
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand Alone/Non-integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange
Type MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases
as the temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4522
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described above. However, one is located before the supercharger at the air cleaner for
standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in
the intake manifold. The IAT2 sensor located after the supercharger provides air temperature
information to the PCM to control border-line spark and to help determine intercooler efficiency.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4528
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4529
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4530
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
ENGINE OIL PRESSURE (EOP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor.
- To install, tighten to 21 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4537
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4538
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable cam timing (VCT) applications the EOT input is used to adjust the VCT control gains
and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM will begin reducing power by disabling engine cylinders.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4539
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5.
Remove the EOT sensor. Discard the O-ring seal.
- To install, tighten to 21 Nm (15 lb-ft).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
4544
Oxygen Sensor: Harness Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
4545
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
4546
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
4547
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
4548
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
4549
View 151-9 Transmission - 6HP26 Automatic
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 4552
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 4553
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 4554
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4555
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage
according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in
the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the
PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during
closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater
by providing the ground when the proper conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor
(HO2S) electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 4558
3. Using the special tool, remove the HO2S.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 4559
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Exploded View
Socket, Exhaust Gas Oxygen Sensor
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 4560
3. Using the special tool, remove the catalyst monitor sensor.
- To install, tighten to 46 Nm (34 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch > Page 4565
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 4570
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 4571
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Customer Interest: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Customer Interest: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 4580
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 4586
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Throttle Position Sensor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Motor: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Throttle Position Sensor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page
4592
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Throttle Position Sensor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page
4598
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
4599
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
4600
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body (ETB) Position Sensor > Page 4603
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
4604
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4608
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4609
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4610
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4611
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4612
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information generated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor > Page 4617
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency
that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity,
the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor
generates a signal with a higher frequency. The PCM uses the frequency signal generated by the
VSS (and other inputs) to control such parameters as fuel injection, ignition control,
transmission/transaxle shift scheduling, and torque converter clutch scheduling.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05
> Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05
> Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 4626
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 4632
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 4633
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 4634
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 4637
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 4638
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4642
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4643
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4644
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4645
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4646
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 06-19-8 >
Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 06-19-8 >
Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 4655
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 06-19-8 >
Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 4656
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 06-19-8 >
Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 4657
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 05-15-8 >
Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: Customer Interest Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > Customer Interest for Variable Valve Timing Actuator: > 05-15-8 >
Aug > 05 > Engine - Ticking/Knocking Noises > Page 4662
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up
Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 4668
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 4669
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: >
06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up Rattle > Page 4670
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: >
05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - Ticking/Knocking Noises
TSB 05-15-8
08/08/05
TICKING AND/OR KNOCKING NOISE FROM ENGINE - 4.6L/5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and/or knocking noise after reaching normal operating temperature. The noise may be described
as "ticks", "taps", "knocks", or "thumps". In some cases the noise may be a normal characteristic of
these engines. In other cases the noise may require further investigation. Sorting out and defining
the noise as reported by the customer is important to successfully diagnose and/or repair the
condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with.
2. Determine what environment the customer is in when the noise is most noticeable to them
(inside passenger compartment, next to building with/without the driver and/or passenger window
open, or beside the wheel well). Validate by using your own perception.
3. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
4. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID.
5. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
6. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Valve Timing Actuator: >
05-15-8 > Aug > 05 > Engine - Ticking/Knocking Noises > Page 4675
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking/tapping noise noticeable at any engine RPM/temperature and is
audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise
can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary.
If isolated, replace all the lifters, intake and exhaust, only on the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park/neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral.
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the camshaft "In-Vehicle Repair" procedure
found in the Workshop Manual.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6007 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 4678
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Page 4679
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAM TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At
idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air
flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the
PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems
provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS
systems also have the added benefit of improved torque. In addition, some VCT system
applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The
elimination of the EGR system is accomplished by controlling the overlap time between the intake
valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used.
Variable Cam Timing (VCT) System
Variable Cam Timing System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments.
1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant
temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system will not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It will continually update the
VCT solenoid duty cycle until the desired position is achieved. A difference between the desired
and actual camshaft position represents a position error in the PCM VCT control loop. The PCM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Page 4680
will disable the VCT and place the camshaft in a default position if a fault is detected. A related
DTC will also be set when the fault is detected.
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the cam timing. One
half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing
chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow
of oil is shifted from one side of the chamber to the other, the differential change in oil pressure
forces the camshaft to rotate in either a advance or retard position depending on the oil flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Service and Repair
Variable Valve Timing Solenoid: Service and Repair
VARIABLE CAMSHAFT TIMING OIL CONTROL SOLENOID
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the variable camshaft timing (VCT) oil
control solenoid electrical connector. 3. Remove the VCT oil control solenoid grommet. 4. Remove
the bolt and the VCT oil control solenoid. Discard the O-ring seal.
- To install, tighten to 5 Nm (44 lb-in).
- Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information generated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 4688
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency
that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity,
the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor
generates a signal with a higher frequency. The PCM uses the frequency signal generated by the
VSS (and other inputs) to control such parameters as fuel injection, ignition control,
transmission/transaxle shift scheduling, and torque converter clutch scheduling.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Description and Operation
Air Diverter Solenoid: Description and Operation
Secondary Air Injection Bypass Solenoid
For information on the secondary air injection bypass solenoid, refer to the description of the
Secondary Air Injection (AIR) Systems.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation
Air Diverter Valve: Description and Operation
AIR DIVERTER VALVE
Air Injection (AIR) Diverter Valve
The secondary AIR diverter valve is used with the electric AIR pump to provide on/off control of air
to the exhaust manifold and catalytic converter. When the electric AIR pump is on and vacuum is
supplied to the AIR diverter valve, air passes the integral check valve disk. When the electric AIR
pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is
held on the seat and stops air from being drawn into the exhaust system and prevents the back
flow of the exhaust into the secondary AIR system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Description and Operation
Air Injection Pump: Description and Operation
Electric Secondary Air Injection Pump
For information on the electric secondary air injection pump, refer to the description of the
Secondary Air Injection (AIR) Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation
Catalytic Converter: Description and Operation
Catalyst and Exhaust Systems Overview
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
carbon dioxide (C02) and water vapor (H20). However~ it also contains carbon monoxide (CO)
oxides of nitrogen (NO) hydrogen (H) and various unburned hydrocarbons (HCs). CO NO 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 front heated
oxygen sensor (HO2S) rear exhaust pipe catalyst HO2S a muffler and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications more than one catalyst will be used between the front and rear exhaust pipes.
Catalytic converter efficiency is monitored by the on-board diagnostic (OBD) system strategy in the
PCM. For information on the OBD catalyst monitor refer to the description for the Catalyst
Efficiency Monitor in this section.
The number of HO2S used in the exhaust stream and the location of these sensors depend on the
vehicle emission certification level (i.e. LEV ULEV PZEV). On most vehicles only 2 HO2S are used
in an exhaust stream. The front sensors (HO2S1 1/H02S21) before the catalyst will be used for
primary fuel control while the ones afier the catalyst (H02S12/H02S22) will be used to monitor
catalyst efficiency. However some partial zero emission vehicles (PZEV) will use 3 HO2S sensors
for each engine bank. The stream 1 sensors (HO2S1 1/H02S21) located before the catalyst are
used for primary fuel control the stream 2 sensors (H02S12/H02S22) are used to monitor the
light-off catalyst and the stream 3 sensors (H02S13/H02S23) located afier the catalyst are used for
long term fuel trim control to optimize catalyst efficiency (fore afi oxygen sensor control). Current
PZEV vehicles use only a 4-cylinder engine so only the Bank 1 HO2S will be used.
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
ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust
gases come in contact with the catalyst they are changed into mostly harmless products. The
catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components
so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up converter efficiency rises rapidly. The point at which conversion efficiency
exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 301°C
(475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the
exhaust
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4703
manifold as possible. Because the light off catalyst is located close to the exhaust manifold it will
light off faster and reduce emissions quicker than the catalyst located under the body. Once the
catalyst lights of{ the catalyst will quickly reach the maximum conversion efficiency for that catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
A TWC requires a stoichiometric fuel ratio 14.7 pounds of air to 1 pound of fuel (14.7: 1) for high
conversion efficiency. In order to achieve these high efficiencies the air/fuel ratio must be tightly
controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly
decrease the conversion efficiency. For example a rich mixture will decrease the HC and CO
conversion efficiency while a lean mixture will decreases the NO conversion efficiency.
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 (NO) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter past
another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally the exhaust
emissions are directed to the atmosphere through an exhaust tailpipe.
Note: On some partial zero emission vehicles (PZEV) there will be a total of 3 HO2S in the exhaust
stream. One near the exhaust manifold (stream 1) one in the middle of the light-off catalyst (stream
2) and the third (stream 3) is mounted afier the light-off catalyst.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4704
Underbody Catalyst
The underbody catalyst is located afier the light off catalyst. The underbody catalyst may be in-line
with the light off catalyst or the underbody catalyst may be common to 2 light off catalysts forming a
Y pipe configuration.
Three-Way Catalytic Converter
The 3-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 NO. The 3-way conversion can be best accomplished by always
operating the engine air fuel/ratio at or close to stoichiometry.
Exhaust Manifold Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Heated Oxygen Sensors (HO2S)
The HO2S provide the powertrain control module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas. For information on the HO2S refer to PCM Inputs
in this section.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine and also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4709
Canister Purge Control Valve: Description and Operation
Evaporative Emission (EVAP) Canister Purge Valve
For information on the EVAP canister purge valve, refer to the description of the Evaporative
Emission Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4710
Canister Purge Control Valve: Service and Repair
EVAPORATIVE EMISSION CANISTER PURGE VALVE
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
1. Disconnect the battery ground cable. 2. Disconnect the evaporative emissions (EVAP) canister
purge solenoid electrical connector. 3. Disconnect the 2 fuel vapor tubes. 4. Remove the EVAP
canister purge solenoid from the bracket. 5. To install, reverse the removal procedure.
- Leak Test the system.
- Carry out the evaporative emissions repair verification drive cycle. See: Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service and Repair
Evaporative Emission Control Canister: Service and Repair
EVAPORATIVE EMISSION CANISTER
Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service and Repair > Page 4714
Part 2
Exploded View
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the spare tire. 4. Disconnect the evaporative emissions (EVAP) canister vent solenoid
electrical connector. 5. Disconnect the fuel vapor tube from the EVAP canister. 6. Disconnect the
fuel vapor vent tube from the dust separator. 7. Remove the 4 bolts and the EVAP canister
assembly.
- To install, tighten to 13 Nm (10 lb-ft).
8. Place the EVAP canister bracket assembly on a clean work surface.
9. Disconnect the EVAP filter vapor tube from the EVAP canister.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service and Repair > Page 4715
10. Disconnect the hose from the dust separator.
11. Release the tabs and remove the EVAP canister from the bracket. 12. To install, reverse the
removal procedure.
- Leak test the system.
- Carry out the evaporative emissions repair verification drive cycle. See: Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Solenoid, Evaporative System > Component Information > Description and Operation
Leak Detection Solenoid: Description and Operation
CANISTER VENT (CV) SOLENOID
Typical Canister Vent (CV) Solenoid
For information on the CV solenoid, refer to the description of the Evaporative Emission Systems.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations > Page 4722
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations > Page 4723
Leak Detection Valve: Description and Operation
CANISTER VENT (CV) SOLENOID
Typical Canister Vent (CV) Solenoid
During the EVAP leak check monitor, the CV solenoid seals the EVAP canister from the
atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in
the fuel tank during the EVAP leak check monitor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations > Page 4724
Leak Detection Valve: Service and Repair
EVAPORATIVE EMISSION CANISTER VENT SOLENOID
Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations > Page 4725
Part 2
Exploded View
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the spare tire. 4. Disconnect the evaporative emissions (EVAP) canister vent solenoid
electrical connector. 5. Disconnect the fuel vapor tube from the EVAP canister. 6. Disconnect the
fuel vapor vent tube from the dust separator. 7. Remove the 4 bolts and the EVAP canister
assembly.
- To install, tighten to 13 Nm (10 lb-ft).
8. Place the EVAP canister bracket assembly on a clean work surface.
9. Disconnect the hoses and remove the EVAP canister vent solenoid from the EVAP canister
bracket.
10. To install, reverse the removal procedure.
- Carry out the evaporative emission system leak test. See: Testing and Inspection/Evaporative
Emission System Leak Test
- Carry out the evaporative emissions repair verification drive cycle. See: Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Description and Operation
EGR Control Module: Description and Operation
EGR SYSTEM MODULE (ESM)
Overview
EGR System Module (ESM)
The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional
DPFE system, however the various system components have been integrated into a single
component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake
manifold with a metal gasket that forms the measuring orifice. This arrangement increases system
reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to
the intake side of the EGR valve, the downstream pressure signal measures manifold absolute
pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a
traditional DPFE system.
The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional
tests that monitor various aspects of the EGR system operation.
First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405
P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403).
NOTE: EGR normally has large amounts of water vapor that are the result of the engine
combustion process. During cold ambient temperatures, under some circumstances, water vapor
can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to
prevent MIL illumination for temporary freezing, the following logic is used.
If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for
the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will
not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines
that the malfunction is no longer present, the EGR system will be enabled and normal system
operation will be restored.
If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor
is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the
malfunction has been detected on 2 consecutive driving cycles.
After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the
low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will
deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is
very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is
evaluated to determine the amount of EGR system restriction. If the differential pressure is below a
calibrated threshold, a low flow malfunction is indicated (P0401/P0406).
Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero
requested EGR flow to carry out the high flow check. If the differential pressure exceeds a
calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR
valve seat (P0402).
If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the
altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run
reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle
leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will
attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is
disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will
be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles
for the EGR monitor to be set to a ready condition.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
EGR VACUUM REGULATOR (EVR) SOLENOID
For information on the EVR solenoid, refer to Exhaust Gas Recirculation Systems Differential
Pressure Feedback EGR (DPFE) System in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation
EGR Tube: Description and Operation
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 2 pressure pick-up tubes. The internal metering orifice creates a
measurable pressure drop across it as the EGR valve opens and closes. This pressure differential
across the orifice is picked up by the DPFE sensor which provides feedback to the PCM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation
EGR Valve: Description and Operation
EXHAUST GAS RECIRCULATION (EGR) VALVE
Typical EGR Valve
Test Graph
The EGR valve in the DPFE system is a conventional, vacuum-actuated. 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 repair specifications on flow rate is
impractical. The on-board diagnostic (OBD) system monitors the EGR valve function and triggers a
diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not
measured directly as part of the diagnostic procedures.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 4743
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 4744
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV
Heater > Component Information > Service and Repair
PCV Heater: Service and Repair
POSITIVE CRANKCASE VENTILATION (PCV) HEATER ELEMENT
Removal
1. Disconnect the battery ground cable. 2. Disconnect the positive crankcase ventilation (PCV)
heater element electrical connector.
3. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to
remove any foreign material from the
connector retaining clip area before separating from the tube.
Disconnect the quick release couplings and remove the PCV tube. Push the fitting toward the tube to release pressure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV
Heater > Component Information > Service and Repair > Page 4749
- Push the release tab clockwise.
- Disconnect the quick release coupling.
4. Remove the bolt and the PCV heater element.
- Discard the O-ring seal.
Installation
1. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the PCV heater element and the bolt. Tighten to 10 Nm (89 lb-in).
2. CAUTION: Make sure the quick release coupling clicks into place when installing the tube. To
make sure that the quick release coupling
is fully seated, pull on the tube.
NOTE: Apply clean engine oil to the end of the tube before connecting the coupling.
Position the PCV tube and connect the quick release couplings.
3. Connect the PCV heater element electrical connector. 4. Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Description and Operation
EGR Control Module: Description and Operation
EGR SYSTEM MODULE (ESM)
Overview
EGR System Module (ESM)
The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional
DPFE system, however the various system components have been integrated into a single
component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake
manifold with a metal gasket that forms the measuring orifice. This arrangement increases system
reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to
the intake side of the EGR valve, the downstream pressure signal measures manifold absolute
pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a
traditional DPFE system.
The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional
tests that monitor various aspects of the EGR system operation.
First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405
P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403).
NOTE: EGR normally has large amounts of water vapor that are the result of the engine
combustion process. During cold ambient temperatures, under some circumstances, water vapor
can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to
prevent MIL illumination for temporary freezing, the following logic is used.
If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for
the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will
not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines
that the malfunction is no longer present, the EGR system will be enabled and normal system
operation will be restored.
If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor
is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the
malfunction has been detected on 2 consecutive driving cycles.
After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the
low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will
deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is
very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is
evaluated to determine the amount of EGR system restriction. If the differential pressure is below a
calibrated threshold, a low flow malfunction is indicated (P0401/P0406).
Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero
requested EGR flow to carry out the high flow check. If the differential pressure exceeds a
calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR
valve seat (P0402).
If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the
altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run
reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle
leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will
attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is
disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will
be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles
for the EGR monitor to be set to a ready condition.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) System
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM
Differential Pressure Feedback EGR (DPFE) System Operation
The differential pressure feedback EGR system consists of a differential pressure feedback EGR
sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain
control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as
follows:
1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or
cylinder head temperature (CHT) sensor, intake air
temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft
position (CKP) sensor to provide information on engine operating conditions to the PCM. The
engine must be warm, stable, and running at a moderate load and RPM before the EGR system is
activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a
failure is detected in an EGR component or EGR required input.
2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then
determines the desired pressure drop across the
metering orifice required to achieve that flow and outputs the corresponding signal to the EVR
solenoid.
3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle
the more vacuum the solenoid diverts to the EGR
valve.
4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and
begins to lift the EGR valve pintle off its seat, causing
exhaust gas to flow into the intake manifold.
5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice.
With one side of the orifice exposed to exhaust
backpressure and the other to the intake manifold, a pressure drop is created across the orifice
whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the
metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets
a desired pressure drop across the metering orifice to achieve the desired EGR flow.
6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a
proportional voltage signal (0 to 5 volts) to the PCM.
The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 4762
Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback
EGR (DPFE) Sensor
DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Differential Pressure Feedback EGR (DPFE) Sensor
For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation
Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (DPFE) System > Page 4763
Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential
Pressure Feedback EGR (DPFE) Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR
Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and
uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Description and Operation
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that
relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic
procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and
HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel
Pressure Test Kit #134-R0087 or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
.......................................................... 600 - 650 RPM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4780
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4781
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4782
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4783
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4784
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4785
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4786
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4787
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4788
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4789
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4790
Accelerator Pedal: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4791
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4792
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4793
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4794
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4795
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4796
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4797
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4798
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4799
Accelerator Pedal: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4800
127-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4801
127-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal - Fixed
Accelerator Pedal: Service and Repair Accelerator Pedal - Fixed
ACCELERATOR PEDAL - FIXED
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the accelerator pedal position sensor
electrical connector. 3. Remove the 3 bolts and the accelerator pedal assembly.
- To install, tighten to 25 Nm (18 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal - Fixed > Page 4804
Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable
ACCELERATOR PEDAL - ADJUSTABLE
Removal and Installation
CAUTION: The brake pedal and the accelerator pedal must be in the same position when installing
a new cable or a new pedal. The pedals must be in the all the way forward or the all the way
rearward position.
1. Disconnect the battery ground cable. 2. Disconnect the accelerator pedal position sensor
electrical connector. 3. Remove the 3 nuts and the accelerator pedal assembly.
- To install, tighten to 25 Nm (18 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 4808
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 4809
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
AIR CLEANER INTAKE PIPE
Exploded View
Removal and Installation
1. Remove the air cleaner element.
2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air
cleaner intake pipe to release the air cleaner intake pipe
from the air cleaner assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner
Fresh Air Duct/Hose > Component Information > Service and Repair > Page 4814
3. Remove the air cleaner intake tube assembly.
4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Exploded View
Removal and Installation
1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner
element from the air cleaner element tray.
3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure
to do so will result in unusual engine
noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4821
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4822
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4823
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4824
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Capacity Specifications
Fuel: Capacity Specifications
Fuel Tank Capacity ..............................................................................................................................
............................................... 28 gallons (106 liters)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Capacity Specifications > Page 4829
Fuel: Fluid Type Specifications
Fuel Type .............................................................................................................................................
.................................................................. 87 Octane
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator >
Component Information > Description and Operation
Fuel Filler Cap Warning Indicator: Description and Operation
FUEL CAP INDICATOR LAMP
The fuel cap indicator lamp (FCIL) is a communications network message sent by the PCM. The
PCM sends the message to illuminate the lamp when the strategy determines that there is a failure
in the vapor management system due to the fuel filler cap not being sealed properly. This would be
detected by the inability to pull vacuum in the fuel tank, after a fueling event.
NOTE: The FCIL on the Crown Victoria/Grand Marquis, Explorer Sport Trac, and Ranger is a
dedicated output signal that is controlled by the PCM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The electrical connector is located on the LH frame rail under the driver side door.
Disconnect the electrical connector.
3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for
approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition
switch to the OFF position.
6. When fuel system service is complete, connect the electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON.
Select the appropriate vehicle and engine qualifier.
Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset.
9. Start the vehicle and check the fuel system for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension
Technical Service Bulletin # 07M08 Date: 071211
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4845
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated by December 11 2007.
FSA VIN LIST ACTIVATED?
No
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition.
SOLD VEHICLES
Only vehicles under this program that have stuck fuel injectors should be repaired.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4846
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed prior to the date of the Customer Notification Letter (or after the date of the letter if
an emergency repair was made away from the servicing dealer), provided the repair occurred
within the 11 year/120,000 mile guidelines. Refund claims that include other non-covered repairs,
or those judged by Ford to be excessive, will not be accepted for reimbursement.
^ The refund period for repairs performed prior to the date of the Customer Notification Letter will
expire on June 30, 2008. After June 30, 2008, only emergency repairs are eligible for
reimbursement.
^ Refund Claiming Information. (Submit on separate repair line.)
- Program Code: 07M08 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from Special Service Support Center. Refer to ACESII manual
for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your part requirements through normal order
processing channels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4847
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
Attachment III - Technical Information
OVERVIEW This extended coverage program only applies to fuel injectors that are found to be
stuck open or stuck closed. Stuck fuel injectors can cause a hard start, misfire, hesitation, rough
running and an illuminated malfunction indicator lamp (MIL). During diagnosis, if other concerns are
found that are not related to stuck fuel injectors, they will not be covered under this program and
are the responsibility of the customer if the vehicle has exceeded the time and mileage of other
applicable warranty coverage.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
NOTE:
If a fuel injector has not failed, diagnosis will have to be charged to the causal part number and any
remaining coverage that the causal part may have if it is still under warranty. If the warranty on the
causal part has expired, the diagnosis and repair costs will be the customer's responsibility.
SERVICE PROCEDURE
This procedure is designed to determine, as quickly as possible, if a fuel injector has failed and
requires replacement.
INSPECTION
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE AN OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT.
HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED.
FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE
IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL TUBES
OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Connect the Integrated Diagnostic System (IDS) to the vehicle. Start a new session on IDS (DO
NOT use a previous session). Perform Self Test-Continuous or KOEO only and retrieve the DTCs.
Record all fuel system-related DTCs on the repair order.
^ If any of the following DTCs are present or pending, proceed to the next step.
^ If none of the following DTCs are present or pending and the vehicle exhibits a misfire, the
concern may not be caused by a fuel injector. Proceed with normal diagnostics.
- P0171 System too lean - bank 1
- P0172 System too rich - bank 1
- P0174 System too lean - bank 2
- P0175 System too rich - bank 2
- P0300 - P0308 Random and or Specific Cylinder Misfire
- P0316 Misfire detected on startup in first 1,000 revolutions
- P219502 sensor signal biased/stuck lean (H02511)
- P219602 sensor signal biased/stuck rich (H02511)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4848
- P219702 sensor signal biased/stuck lean (H02521)
- P2198 02 sensor stuck biased/stuck rich (H02521)
CAUTION:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs in any open orifices or tubes.
NOTE:
Be careful not to disengage any of the fuel injectors from the fuel rail. This could allow air to enter
the fuel system which will not allow the diagnostic tests to run. If a fuel injector is disengaged from
the fuel rail, it will be necessary to reinstall the fuel rail and run the engine to purge any air from the
fuel system.
2. Follow the steps listed below to lift up the fuel rail. See Figure 1.
A. Remove the PCV hose.
B. Disconnect the vacuum hose.
C. Remove the 4 fuel rail bolts.
D. Lift up the fuel rail enough to place the 100-ml beakers and stoppers from tool kit #
TKIT-2007F1-FLM under each fuel injector.
3. Tie-strap all of the fuel injectors to the fuel rail. See Figure 2.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4849
4. Place a 100-mi beaker and stopper from tool kit # TKIT-2007F1-FLM under each fuel injector.
Make sure that all of the fuel injector-to-rail locking clips and tie straps are installed. See Figure 3.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
5. Cycle the ignition key to the ON position.
^ If any fuel injector leaks, turn the key OFF and proceed to the next step.
^ If no fuel leaks out of the injectors, turn the ignition key OFF and proceed to Step 10.
6. Remove the beakers and tie straps from all fuel injectors.
7. Replace the leaking fuel injector (upper and lower 0-rings are included with the new fuel
injector).
8. Replace the lower 0-rings on the other seven (7) fuel injectors.
9. Change the engine oil and engine oil filter and proceed to Step 25 to install the fuel rail.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
10. Perform the Relative Injector Flow test using the IDS. While the test is running, examine the
beakers and note which injectors (if any) have low flow, no flow or Oms.
^ If a no flow, low flow or Oms injector is found, proceed to the next step to depressurize the fuel
system prior to fuel injector removal.
^ If no injectors are found to have low flow, no flow or Oms, proceed to Step 23.
11. Remove the beakers from all of the fuel injectors.
12. Install the fuel rail. See Figure 1.
A. Install the PCV hose.
B. Connect the vacuum hose.
C. Install the 4 fuel rail bolts.
13. Select Datalogger in IDS and make the following selections:
^ Powertrain
^ Engine
^ Then select the tick mark to proceed.
14. Select the FP # pid and select the tick mark to proceed to the display screen.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4850
15. Toggle the FP# pid to OFF by highlighting FP # in the display and using the - sign selection on
the right side of the screen. This will turn off the fuel pump.
16. Start the engine.
17. Allow the engine to stall and then turn the key to the OFF position.
18. Lift up the fuel rail so the failed fuel injector can be replaced. See Figure 1.
A. Remove the PCV hose.
B. Disconnect the vacuum hose.
C. Remove the 4 fuel rail bolts.
D. Lift the fuel rail up enough to replace the failed fuel injector.
19. Remove the ties strap and fuel injector-to-rail locking clip from the failed injector.
20. Replace the failed injector with a new fuel injector (upper and lower 0-rings are included with
the new fuel injector).
21. Replace the lower 0-rings on the other seven (7) fuel injectors.
22. Install a tie strap on the new injector and install the beakers on all eight (8) injectors. See
Figures 2 and 3.
23. Cycle the ignition key to the ON position.
^ If any fuel injector leaks, call the Special Service Support Center for further direction.
^ If no fuel leaks out of the injectors, turn the key OFF and proceed to the next step.
24. Remove all of the tie straps from the fuel rail and remove the beakers.
25. Install the fuel rail. See Figure 1.
A. Install the PCV hose.
B. Connect the vacuum hose.
C. Install the 4 fuel rail bolts and tighten to 10 Nm (89 lb-in).
26. Clear the DTCs.
27. Start the engine and check for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4851
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Recalls: > 07M08 > Dec > 07 > Campaign - Fuel Injector Warranty Extension >
Page 4852
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up
Rattle
Fuel Injector: Customer Interest Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up
Rattle > Page 4858
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up
Rattle > Page 4859
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 06-19-8 > Oct > 06 > Engine - Ticking/Knocking/Start Up
Rattle > Page 4860
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's
Fuel Injector: Customer Interest Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 4865
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 4866
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 4867
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension
Technical Service Bulletin # 07M08 Date: 071211
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4873
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated by December 11 2007.
FSA VIN LIST ACTIVATED?
No
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition.
SOLD VEHICLES
Only vehicles under this program that have stuck fuel injectors should be repaired.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4874
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed prior to the date of the Customer Notification Letter (or after the date of the letter if
an emergency repair was made away from the servicing dealer), provided the repair occurred
within the 11 year/120,000 mile guidelines. Refund claims that include other non-covered repairs,
or those judged by Ford to be excessive, will not be accepted for reimbursement.
^ The refund period for repairs performed prior to the date of the Customer Notification Letter will
expire on June 30, 2008. After June 30, 2008, only emergency repairs are eligible for
reimbursement.
^ Refund Claiming Information. (Submit on separate repair line.)
- Program Code: 07M08 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from Special Service Support Center. Refer to ACESII manual
for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your part requirements through normal order
processing channels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4875
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
Attachment III - Technical Information
OVERVIEW This extended coverage program only applies to fuel injectors that are found to be
stuck open or stuck closed. Stuck fuel injectors can cause a hard start, misfire, hesitation, rough
running and an illuminated malfunction indicator lamp (MIL). During diagnosis, if other concerns are
found that are not related to stuck fuel injectors, they will not be covered under this program and
are the responsibility of the customer if the vehicle has exceeded the time and mileage of other
applicable warranty coverage.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
NOTE:
If a fuel injector has not failed, diagnosis will have to be charged to the causal part number and any
remaining coverage that the causal part may have if it is still under warranty. If the warranty on the
causal part has expired, the diagnosis and repair costs will be the customer's responsibility.
SERVICE PROCEDURE
This procedure is designed to determine, as quickly as possible, if a fuel injector has failed and
requires replacement.
INSPECTION
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE AN OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT.
HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED.
FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE
IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL TUBES
OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Connect the Integrated Diagnostic System (IDS) to the vehicle. Start a new session on IDS (DO
NOT use a previous session). Perform Self Test-Continuous or KOEO only and retrieve the DTCs.
Record all fuel system-related DTCs on the repair order.
^ If any of the following DTCs are present or pending, proceed to the next step.
^ If none of the following DTCs are present or pending and the vehicle exhibits a misfire, the
concern may not be caused by a fuel injector. Proceed with normal diagnostics.
- P0171 System too lean - bank 1
- P0172 System too rich - bank 1
- P0174 System too lean - bank 2
- P0175 System too rich - bank 2
- P0300 - P0308 Random and or Specific Cylinder Misfire
- P0316 Misfire detected on startup in first 1,000 revolutions
- P219502 sensor signal biased/stuck lean (H02511)
- P219602 sensor signal biased/stuck rich (H02511)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4876
- P219702 sensor signal biased/stuck lean (H02521)
- P2198 02 sensor stuck biased/stuck rich (H02521)
CAUTION:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs in any open orifices or tubes.
NOTE:
Be careful not to disengage any of the fuel injectors from the fuel rail. This could allow air to enter
the fuel system which will not allow the diagnostic tests to run. If a fuel injector is disengaged from
the fuel rail, it will be necessary to reinstall the fuel rail and run the engine to purge any air from the
fuel system.
2. Follow the steps listed below to lift up the fuel rail. See Figure 1.
A. Remove the PCV hose.
B. Disconnect the vacuum hose.
C. Remove the 4 fuel rail bolts.
D. Lift up the fuel rail enough to place the 100-ml beakers and stoppers from tool kit #
TKIT-2007F1-FLM under each fuel injector.
3. Tie-strap all of the fuel injectors to the fuel rail. See Figure 2.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4877
4. Place a 100-mi beaker and stopper from tool kit # TKIT-2007F1-FLM under each fuel injector.
Make sure that all of the fuel injector-to-rail locking clips and tie straps are installed. See Figure 3.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
5. Cycle the ignition key to the ON position.
^ If any fuel injector leaks, turn the key OFF and proceed to the next step.
^ If no fuel leaks out of the injectors, turn the ignition key OFF and proceed to Step 10.
6. Remove the beakers and tie straps from all fuel injectors.
7. Replace the leaking fuel injector (upper and lower 0-rings are included with the new fuel
injector).
8. Replace the lower 0-rings on the other seven (7) fuel injectors.
9. Change the engine oil and engine oil filter and proceed to Step 25 to install the fuel rail.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
10. Perform the Relative Injector Flow test using the IDS. While the test is running, examine the
beakers and note which injectors (if any) have low flow, no flow or Oms.
^ If a no flow, low flow or Oms injector is found, proceed to the next step to depressurize the fuel
system prior to fuel injector removal.
^ If no injectors are found to have low flow, no flow or Oms, proceed to Step 23.
11. Remove the beakers from all of the fuel injectors.
12. Install the fuel rail. See Figure 1.
A. Install the PCV hose.
B. Connect the vacuum hose.
C. Install the 4 fuel rail bolts.
13. Select Datalogger in IDS and make the following selections:
^ Powertrain
^ Engine
^ Then select the tick mark to proceed.
14. Select the FP # pid and select the tick mark to proceed to the display screen.
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4878
15. Toggle the FP# pid to OFF by highlighting FP # in the display and using the - sign selection on
the right side of the screen. This will turn off the fuel pump.
16. Start the engine.
17. Allow the engine to stall and then turn the key to the OFF position.
18. Lift up the fuel rail so the failed fuel injector can be replaced. See Figure 1.
A. Remove the PCV hose.
B. Disconnect the vacuum hose.
C. Remove the 4 fuel rail bolts.
D. Lift the fuel rail up enough to replace the failed fuel injector.
19. Remove the ties strap and fuel injector-to-rail locking clip from the failed injector.
20. Replace the failed injector with a new fuel injector (upper and lower 0-rings are included with
the new fuel injector).
21. Replace the lower 0-rings on the other seven (7) fuel injectors.
22. Install a tie strap on the new injector and install the beakers on all eight (8) injectors. See
Figures 2 and 3.
23. Cycle the ignition key to the ON position.
^ If any fuel injector leaks, call the Special Service Support Center for further direction.
^ If no fuel leaks out of the injectors, turn the key OFF and proceed to the next step.
24. Remove all of the tie straps from the fuel rail and remove the beakers.
25. Install the fuel rail. See Figure 1.
A. Install the PCV hose.
B. Connect the vacuum hose.
C. Install the 4 fuel rail bolts and tighten to 10 Nm (89 lb-in).
26. Clear the DTCs.
27. Start the engine and check for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4879
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 >
Campaign - Fuel Injector Warranty Extension > Page 4880
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle
Fuel Injector: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 4885
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 4886
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 4887
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
Fuel Injector: All Technical Service Bulletins Fuel System - MIL ON/Rough Idle/Long
Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4892
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4893
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel
System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4894
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle
Fuel Injector: All Technical Service Bulletins Engine - Ticking/Knocking/Start Up Rattle
TSB 06-19-8
10/02/06
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD: 2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUE Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking
and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The
noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a
normal characteristic of these engines. In other cases the noise may require further investigation.
Sorting out and defining the noise as reported by the customer is important to successfully
diagnose and I or repair the condition.
ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer
is concerned with. The customer should be interviewed to get their detailed perception and
description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the
engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the
symptom. Refer to the following Service Procedure to help determine the source of the noise and if
a repair is needed.
SERVICE PROCEDURE
NOTE
READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.
NOTE
THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS,
WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN
SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT
CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.
PRE-CHECKS
1. Make sure you have a detailed description of the noise the customer is concerned with, including
whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM),
and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of
"normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine
what environment the customer is in when the noise is most noticeable to them (inside passenger
compartment, next to building with / without the driver and / or passenger window open, or beside
the wheel well). Validate by using your own perception.
2. Compare the noise generated with a new vehicle, if available, with an ENGINE build date of
3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator
vehicles.
3. Diagnose noise when engine is at normal operating temperature (Oil at 160° F (71° C) or
above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil
temperature (EOT) PID. Startup rattle may only occur with cold oil.
4. Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure
drop. Look for aftermarket brands not recognized in the market or a production filter that has gone
beyond the standard Ford recommended change interval.
5. Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE
5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.
Once the above pre-checks are complete, check for sound level from the following components, in
the order listed. Compare the sound from these components to the noise the customer is
concerned with, to determine the source of the noise.
INJECTION / FUEL SYSTEM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 4900
Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is
recognized at the top of the engine.
VALVE TRAIN
Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and
is audible through the wheel well or an open hood. However, with the hood down, lash adjuster
noise can be heard as a light tapping noise through the wheel well and is considered normal.
Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank,
focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel
well sound level to another comparable vehicle.
Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move
the probe from front to rear if necessary. If isolated, only replace the intake and exhaust lifters on
the affected cylinder bank.
VARIABLE CAM TIMING
The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal
operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral).
However, it may be masked by or mistaken for other noises generated from either injector firing or
a malfunctioning valve train as described above. The noise does not affect performance or
durability of the part.
VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the
wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full
diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The
knock is not prevalent at cold temperature.
To test for VCT noise:
1. Place the transmission in park or neutral
2. Bring engine oil temperature to 160° F (71° C) or above as indicated by the scan tool "EOT" PID.
3. Allow engine to idle, and determine if noise is noticeable.
4. Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).
5. Return engine speed to idle (verify knock returns).
If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine
operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and
Sprocket procedure found in the Workshop Manual, Section 303-01
START UP RATTLE
Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles
may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed
and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If
the engine continues to make the rattle noise after the initial startup do not exchange VCT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061908A 2005 Expedition / 4.5 Hrs.
Navigator 5.4L 3V: Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 4901
061908A 2005 Mustang 4.6L 3V: 2.2 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2005 Super Duty 5.4L 3V: 3.1 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908A 2004-2005 F-150 5.4L 3V: 3.7 Hrs.
Replace Right Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2004-2005 F-150 5.4L 3V: 2.5 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft) Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A
061908B 2005 Super Duty 5.4L 3V: 2.6 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Mustang 4.6L 3V: 2.3 Hrs.
Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser Hrs. (6500A, 6256A,
6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908B 2005 Expedition / 2.7 Hrs.
Navigator 5.4L 3V: Replace Left Bank Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Expedition / 6.7 Hrs.
Navigator 5.4L 3V: Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser
(6500A, 6256A, 6250A, 6020A, 6268B,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 06-19-8 > Oct > 06 > Engine Ticking/Knocking/Start Up Rattle > Page 4902
6266A, 6584A, 9424A)
061908C 2005 Mustang 4.6L 3V: 4.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2005 Super Duty 5.4L 3V: 5.2 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
061908C 2004-2005 F-150 5.4L 3V: 5.5 Hrs.
Replace Both Banks Lash Adjusters And / Or Camshaft Sprocket / Phaser (6500A, 6256A, 6250A,
6020A, 6268B, 6266A, 6584A, 9424A)
MT061908 Claim Additional Labor Actual
Required As Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
6500 (LASH ADJUSTER REPLACEMENT) 42 6A257 (VCT REPLACEMENT)
42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's
Fuel Injector: All Technical Service Bulletins Fuel System - MIL ON/Rough Idle/Long
Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4907
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4908
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 05-13-4 > Jul > 05 > Fuel System MIL ON/Rough Idle/Long Crank/Misfire/DTC's > Page 4909
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension
Technical Service Bulletin # 07M08 Date: 071211
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4915
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated by December 11 2007.
FSA VIN LIST ACTIVATED?
No
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition.
SOLD VEHICLES
Only vehicles under this program that have stuck fuel injectors should be repaired.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4916
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed prior to the date of the Customer Notification Letter (or after the date of the letter if
an emergency repair was made away from the servicing dealer), provided the repair occurred
within the 11 year/120,000 mile guidelines. Refund claims that include other non-covered repairs,
or those judged by Ford to be excessive, will not be accepted for reimbursement.
^ The refund period for repairs performed prior to the date of the Customer Notification Letter will
expire on June 30, 2008. After June 30, 2008, only emergency repairs are eligible for
reimbursement.
^ Refund Claiming Information. (Submit on separate repair line.)
- Program Code: 07M08 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from Special Service Support Center. Refer to ACESII manual
for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your part requirements through normal order
processing channels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4917
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
Attachment III - Technical Information
OVERVIEW This extended coverage program only applies to fuel injectors that are found to be
stuck open or stuck closed. Stuck fuel injectors can cause a hard start, misfire, hesitation, rough
running and an illuminated malfunction indicator lamp (MIL). During diagnosis, if other concerns are
found that are not related to stuck fuel injectors, they will not be covered under this program and
are the responsibility of the customer if the vehicle has exceeded the time and mileage of other
applicable warranty coverage.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
NOTE:
If a fuel injector has not failed, diagnosis will have to be charged to the causal part number and any
remaining coverage that the causal part may have if it is still under warranty. If the warranty on the
causal part has expired, the diagnosis and repair costs will be the customer's responsibility.
SERVICE PROCEDURE
This procedure is designed to determine, as quickly as possible, if a fuel injector has failed and
requires replacement.
INSPECTION
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE AN OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT.
HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED.
FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE
IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL TUBES
OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Connect the Integrated Diagnostic System (IDS) to the vehicle. Start a new session on IDS (DO
NOT use a previous session). Perform Self Test-Continuous or KOEO only and retrieve the DTCs.
Record all fuel system-related DTCs on the repair order.
^ If any of the following DTCs are present or pending, proceed to the next step.
^ If none of the following DTCs are present or pending and the vehicle exhibits a misfire, the
concern may not be caused by a fuel injector. Proceed with normal diagnostics.
- P0171 System too lean - bank 1
- P0172 System too rich - bank 1
- P0174 System too lean - bank 2
- P0175 System too rich - bank 2
- P0300 - P0308 Random and or Specific Cylinder Misfire
- P0316 Misfire detected on startup in first 1,000 revolutions
- P219502 sensor signal biased/stuck lean (H02511)
- P219602 sensor signal biased/stuck rich (H02511)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4918
- P219702 sensor signal biased/stuck lean (H02521)
- P2198 02 sensor stuck biased/stuck rich (H02521)
CAUTION:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs in any open orifices or tubes.
NOTE:
Be careful not to disengage any of the fuel injectors from the fuel rail. This could allow air to enter
the fuel system which will not allow the diagnostic tests to run. If a fuel injector is disengaged from
the fuel rail, it will be necessary to reinstall the fuel rail and run the engine to purge any air from the
fuel system.
2. Follow the steps listed below to lift up the fuel rail. See Figure 1.
A. Remove the PCV hose.
B. Disconnect the vacuum hose.
C. Remove the 4 fuel rail bolts.
D. Lift up the fuel rail enough to place the 100-ml beakers and stoppers from tool kit #
TKIT-2007F1-FLM under each fuel injector.
3. Tie-strap all of the fuel injectors to the fuel rail. See Figure 2.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4919
4. Place a 100-mi beaker and stopper from tool kit # TKIT-2007F1-FLM under each fuel injector.
Make sure that all of the fuel injector-to-rail locking clips and tie straps are installed. See Figure 3.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
5. Cycle the ignition key to the ON position.
^ If any fuel injector leaks, turn the key OFF and proceed to the next step.
^ If no fuel leaks out of the injectors, turn the ignition key OFF and proceed to Step 10.
6. Remove the beakers and tie straps from all fuel injectors.
7. Replace the leaking fuel injector (upper and lower 0-rings are included with the new fuel
injector).
8. Replace the lower 0-rings on the other seven (7) fuel injectors.
9. Change the engine oil and engine oil filter and proceed to Step 25 to install the fuel rail.
NOTE:
If more than 1 fuel injector needs to be replaced for this program, call the Special Service Support
Center for prior approval.
10. Perform the Relative Injector Flow test using the IDS. While the test is running, examine the
beakers and note which injectors (if any) have low flow, no flow or Oms.
^ If a no flow, low flow or Oms injector is found, proceed to the next step to depressurize the fuel
system prior to fuel injector removal.
^ If no injectors are found to have low flow, no flow or Oms, proceed to Step 23.
11. Remove the beakers from all of the fuel injectors.
12. Install the fuel rail. See Figure 1.
A. Install the PCV hose.
B. Connect the vacuum hose.
C. Install the 4 fuel rail bolts.
13. Select Datalogger in IDS and make the following selections:
^ Powertrain
^ Engine
^ Then select the tick mark to proceed.
14. Select the FP # pid and select the tick mark to proceed to the display screen.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4920
15. Toggle the FP# pid to OFF by highlighting FP # in the display and using the - sign selection on
the right side of the screen. This will turn off the fuel pump.
16. Start the engine.
17. Allow the engine to stall and then turn the key to the OFF position.
18. Lift up the fuel rail so the failed fuel injector can be replaced. See Figure 1.
A. Remove the PCV hose.
B. Disconnect the vacuum hose.
C. Remove the 4 fuel rail bolts.
D. Lift the fuel rail up enough to replace the failed fuel injector.
19. Remove the ties strap and fuel injector-to-rail locking clip from the failed injector.
20. Replace the failed injector with a new fuel injector (upper and lower 0-rings are included with
the new fuel injector).
21. Replace the lower 0-rings on the other seven (7) fuel injectors.
22. Install a tie strap on the new injector and install the beakers on all eight (8) injectors. See
Figures 2 and 3.
23. Cycle the ignition key to the ON position.
^ If any fuel injector leaks, call the Special Service Support Center for further direction.
^ If no fuel leaks out of the injectors, turn the key OFF and proceed to the next step.
24. Remove all of the tie straps from the fuel rail and remove the beakers.
25. Install the fuel rail. See Figure 1.
A. Install the PCV hose.
B. Connect the vacuum hose.
C. Install the 4 fuel rail bolts and tighten to 10 Nm (89 lb-in).
26. Clear the DTCs.
27. Start the engine and check for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4921
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 07M08 > Dec > 07 > Campaign Fuel Injector Warranty Extension > Page 4922
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Resistance ...........................................................................................................................................
............................................................. 11 - 18 Ohms
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 4925
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Fuel Injector Flow and Leakage ...................................................................................... Refer to
Pinpoint Test HC13 at Computers and Control Systems.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4928
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4929
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4930
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4931
Fuel Injector: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4932
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4933
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4934
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 4935
Fuel Injector: Description and Operation
Fuel Injectors
For information on the fuel injectors, refer to the description of the Fuel Systems
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 4936
Fuel Injector: Service and Repair
FUEL INJECTORS
Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 4937
Part 2
Exploded View
Disconnect Tool, Spring Lock Coupling
Special Tools(s)
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the air
cleaner inlet pipe. 4. Disconnect the mass air flow (MAF) sensor electrical connector. 5. Disconnect
the brake booster vacuum hose. 6. Disconnect the positive crankcase ventilation (PCV) tube. 7.
Disconnect the crankcase ventilation tube. 8. Disconnect the fuel supply tube spring lock coupling.
9. Disconnect the 8 fuel injector electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 4938
10. Remove the 8 fuel injector-to-fuel rail locking clips 11. Remove the 4 fuel rail bolts and the fuel
rail.
- To install, tighten to 10 Nm (89 lb-in).
12. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary
O-rings can cause the fuel system to leak.
Do not reuse the O-ring seals. Lubricate the O-ring seals with clean engine oil prior to installation.
Remove the fuel injectors and the fuel injector O-ring seals. Discard the O-ring seals.
13. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings
Fuel Line Coupler: Service and Repair Spring Lock Couplings
SPRING LOCK COUPLINGS
Disconnect Tool, Spring Lock Coupling
Special Tool(s)
Disconnect
WARNING:
- Do not smoke, carry lighted tobacco or open flame of any type when working on or near any
fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel 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.
NOTE: These couplings are used to connect the fuel hoses to the fuel supply manifold.
1. Release the fuel system pressure.
2. Remove the fuel tube clip.
3. Install the special tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 4943
4. Close and push the special tool into the open side of the cage.
5. Separate the fitting and remove the special tool.
Connect
1. Inspect and clean both coupling ends. Install new O-ring seals and garter springs if necessary.
- Lubricate the O-ring seals with clean engine oil.
2. Fit the male fitting into the female end and push until the garter spring snaps over the flared end
of the female fitting.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 4944
3. Make sure the coupling is engaged by pulling on the lines and install the safety clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 4945
Fuel Line Coupler: Service and Repair Vapor Tube Fittings
VAPOR TUBE FITTINGS
Disconnect
1. WARNING: The evaporative emission system contains fuel vapor and condensed fuel vapor.
Although not present in large quantities, it
still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery
to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel
vapor or fuel liquid is present in the area. Failure to follow these instructions may result in personal
injury.
Disconnect the battery ground cable.
2. CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line
disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift
the clip out of the connector housing, lifting from the stamped side of the connector body.
Disconnect the vapor tube fitting. Push the connector toward the tube or fitting to release pressure.
- Press the quick connect fitting button and pull the fuel tube to disconnect.
Connect
1. CAUTION:
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
- Make sure the quick connect fitting clicks into place when installing the tube. To make sure that
the quick connect fitting is fully seated, pull on the tube.
NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line
disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift
the clip out of the connector housing, lifting from the stamped side of the connector body.
- Apply clean engine oil to the end of the tube or fitting before connecting.
Connect the quick connect fitting.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 4946
Fuel Line Coupler: Service and Repair Quick Connect Coupling
QUICK CONNECT COUPLING
Disconnect - Type 1
1. 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 can be ignited. Failure to follow these
instructions may result in personal injury.
CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to
remove any foreign material from the connector retaining clip area before separating from the tube.
Disconnect the quick connect fitting. Push the connector toward the tube to release pressure.
- Push the release tab clockwise.
- Disconnect the quick connect fitting.
Disconnect - Type 2
1. 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 can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to
remove any foreign material from the connector retaining clip area before separating from the tube.
NOTE: These couplings are used to connect the fuel tank fuel lines to the front fuel lines and the
pump/sender assembly ports.
Release the fuel system pressure.
2. Press the tab corners to release the locking tab.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 4947
3. Pull the locking tab to the release position.
4. Disconnect the quick connect fitting.
- Push the fitting toward the tube to release pressure.
- Press the tab corners to release the fitting.
- Disconnect the quick connect fitting.
Connect - Type 1
1. NOTE: Apply clean engine oil to the end of the tube or fitting before connecting.
Connect the quick connect fitting.
Connect - Type 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 4948
1. CAUTION: When reusing liquid or Push the fitting toward the tube to release vapor tube
connectors, make sure to use compressed air to
remove any foreign material from the connector retaining clip area before separating from the tube.
NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line
disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift
the clip out of the connector housing, lifting from the stamped side of the connector body.
- Apply clean engine oil to the end of the tube or fitting before connecting.
Connect the tube into the quick connect fitting.
2. CAUTION: Make sure the quick connect fitting clicks into place when installing the tube. To
make sure that the quick connect fitting is
fully seated, pull on the fitting.
Press the locking tab down into the locked position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Pump Module
Fuel Pressure Regulator: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Pump Module > Page 4953
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Pump Module > Page 4954
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Fuel Pump Module > Page 4955
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
the fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve.
One side of the diaphragm senses the 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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Fuel Tank Pressure Transducer Sensor
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Fuel Tank Pressure Transducer Sensor > Page 4960
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 4963
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Diagrams > Page 4964
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Description and Operation
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that
relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic
procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and
HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel
Pressure Test Kit #134-R0087 or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Description and Operation
Fuel Pressure Pulsation Damper: Description and Operation
FUEL RAIL PULSE DAMPER
The fuel rail pulse damper is located on the fuel rail and reduces the fuel system noise caused by
the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold
vacuum to avoid fuel spillage if the pulse damper diaphragm ruptures. (The fuel rail pulse damper
should not be confused with a fuel pressure regulator; it does not regulate the fuel rail pressure.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Description and Operation
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
On some applications there is a pressure test point with a Schrader fitting in the fuel rail that
relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic
procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and
HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel
Pressure Test Kit #134-R0087 or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 4979
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 4980
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal And Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable.
3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the
fuel tank filler pipe.
Disconnect the fuel pump driver module (FPDM) electrical connector.
4. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4984
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair
Fuel Rail: Service and Repair
FUEL RAIL
Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Page 4988
Part 2
Exploded View
Disconnect Tool, Spring Lock Coupling
Special Tool(s)
Removal
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the air
cleaner inlet pipe. 4. Disconnect the mass air flow (MAF) sensor electrical connector. 5. Disconnect
the brake booster vacuum hose. 6. Disconnect the positive crankcase ventilation (PCV) tube. 7.
Disconnect the crankcase ventilation tube. 8. Disconnect the fuel supply tube spring lock coupling.
9. Disconnect the fuel rail pressure and temperature sensor electrical and vacuum connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Page 4989
10. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Remove the 2 bolts and the fuel rail pressure and temperature sensor. Discard the O-ring seal.
- To install, tighten to 4 Nm (35 lb-in).
11. Disconnect the 8 fuel injector electrical connectors. 12. Remove the 8 fuel injector-to-fuel rail
locking clips 13. Remove the 4 fuel rail bolts and the fuel rail.
- To install, tighten to 10 Nm (89 lb-in).
14. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary
O-rings can cause the fuel system to leak.
Do not reuse the O-ring seals. Lubricate the O-ring seals with clean engine oil prior to installation.
Remove the fuel injectors and the fuel injector O-ring seals. Discard the O-ring seals.
15. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair
Fuel Supply Line: Service and Repair
FUEL LINES
Exploded View
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or open flame of any type when working on or near any
fuel-related component. Highly flammable
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 4993
mixtures are always present and can be ignited. Failure to follow these instructions may result in
personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3.
Disconnect the fuel filter outlet tube spring lock coupling. 4. Disconnect the fuel tube-to-fuel rail
spring lock coupling. 5. Disconnect the fuel tube from the position retainer brackets and remove the
fuel tube assembly. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair
Fuel Filler Hose: Service and Repair
FUEL TANK FILLER PIPE
Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 4998
Part 2
Exploded View
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or open flame of any type when working on or near any
fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire
hazard.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable.
3. Remove the fuel tank filler cap.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 4999
4. Remove the 3 screws. 5. Disconnect the fuel tank filler pipe vent tube from the fuel pump
module. 6. Loosen the hose clamp and disconnect the fuel tank filler pipe-to-fuel tank hose. 7.
Disconnect the vapor tube from the evaporative emissions (EVAP) system dust separator.
8. Remove the two bolts from the fuel tank filler pipe support bracket.
- To install, tighten to 15 Nm (11 lb-ft).
9. Remove the fuel tank filler pipe assembly.
10. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir
Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page 5004
Fuel Gauge Sender: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page 5005
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page 5006
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 5007
Fuel Gauge Sender: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 5008
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 5015
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor
Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 5018
Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor
FUEL RAIL TEMPERATURE (FRT) SENSOR
Fuel Rail Temperature (FRT) Sensor
The FRT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Description and Operation > Page 5019
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation
Idle Speed/Throttle Actuator - Electronic: Description and Operation
IDLE AIR CONTROL (IAC) VALVE (APPLICATIONS WITHOUT ETC)
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
NOTE: The IAC valve assembly is NOT ADJUSTABLE and CANNOT BE CLEANED, also some
IAC valves are normally open and others are normally closed. Some IAC valves require engine
vacuum to operate.
The PCM uses the IAC valve assembly to control:
- No touch start.
- Cold engine fast idle for rapid warm-up.
- Idle (corrects for engine load).
- Stumble or stalling on deceleration (provides a dashpot function).
- Over-temperature idle boost.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 5026
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 5027
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 IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in
place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a
conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts
off the electric fuel pump. Once the switch is open it must be manually reset before restarting the
vehicle. Refer to the Owner's Literature for the location of the IFS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 5028
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3.
Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the two bolts and
the IFS switch.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 5032
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 5033
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 5034
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Control Unit > Component Information > Locations
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 5039
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 5040
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal And Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable.
3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the
fuel tank filler pipe.
Disconnect the fuel pump driver module (FPDM) electrical connector.
4. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 5044
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5048
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5049
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5050
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5055
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5056
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
For information on the APP sensor, refer to the description for Torque Based Electronic Throttle
Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5060
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5061
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5062
Typical Drop-in Mass Air Flow (MAF) Sensor
The MAF sensor uses a hot wire sensing element to measure the amount of air entering the
engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F)
above the ambient temperature as measured by a constant cold wire. If the hot wire electronic
sensing element must be replaced, then the entire assembly must be replaced. Replacing only the
element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the mass air flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC),
shift and torque converter clutch scheduling.
Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air
temperature (IAT) sensor.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5063
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical
connector. 3. Remove the 2 bolts and the MAF sensor.
- To install, tighten to 7 Nm (62 lb-in)
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure
Transducer Sensor
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure
Transducer Sensor > Page 5068
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor > Page 5071
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5072
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5076
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail
Pressure Temperature (FRPT) Sensor
Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The fuel return line
to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure
and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both
pressure and temperature signals are used to control the speed of the fuel pump. The speed of the
fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of
the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width
to decrease.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail
Pressure Temperature (FRPT) Sensor > Page 5079
Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor
FUEL RAIL TEMPERATURE (FRT) SENSOR
Fuel Rail Temperature (FRT) Sensor
The FRT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Page 5080
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2
bolts and the FRPT sensor and discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Install a new O-ring seal.
- Lubricate the new O-ring seal prior to installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5084
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5085
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 IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in
place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a
conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts
off the electric fuel pump. Once the switch is open it must be manually reset before restarting the
vehicle. Refer to the Owner's Literature for the location of the IFS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5086
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3.
Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the two bolts and
the IFS switch.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135
Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135
Set > Page 5095
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer
Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer
Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page
5101
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 5102
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 5103
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body (ETB) Position Sensor > Page 5106
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5107
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body System Overview
Throttle Body: Description and Operation Throttle Body System Overview
THROTTLE BODY SYSTEM OVERVIEW
NOTE: This overview is for applications without electronic throttle control (ETC). For ETC
applications, refer to Torque Based Electronic Throttle Control (ETC).
The throttle body system meters air to the engine during idle, part throttle, and wide open throttle
(WOT) conditions. The throttle body system consists of an idle air control (IAC) valve assembly, an
idle air orifice, single or dual bores with butterfly valve throttle plates, and a throttle position (TP)
sensor. One other source of idle air flow is the positive crankcase ventilation (PCV) system. The
combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor
on all applications.
During idle, the throttle body assembly provides a set amount of air flow to the engine through the
idle air passage and the PCV valve. The IAC valve assembly provides additional air when
commanded by the PCM to maintain the proper engine idle speed under varying conditions. The
IAC valve assembly mounts directly to the intake manifold assembly in most applications. Idle
speed is controlled by the PCM and cannot be adjusted.
NOTE: The traditional idle air adjust procedure and the throttle return screw are no longer used on
OBD applications.
Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle
plate. The TP sensor monitors the throttle position and provides a signal to the PCM. Some throttle
body applications provide an air supply channel upstream of the throttle plate to provide fresh air to
the PCV or IAC systems. Other throttle body applications provide individual vacuum taps
downstream of the throttle plate for PCV return, exhaust gas recirculation (EGR), evaporative
emission (EVAP), and miscellaneous control signals.
THROTTLE BODY SYSTEM HARDWARE
The major components of the throttle body assembly include the TP sensor, the IAC valve
assembly, and the throttle body housing assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body System Overview > Page 5112
Throttle Body: Description and Operation Throttle Body Housing
THROTTLE BODY HOUSING
The throttle body housing assembly is a single piece aluminum or plastic casting with an air
passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle
(or closed) position, the throttle lever arm should be in contact with the throttle return stop. The
throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The
setting also establishes the amount of air flow between the throttle plate and bore. To minimize the
closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area.
This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation.
Features of the Throttle Body Assembly include:
1. Idle air control (IAC) valve assembly mounted directly to the throttle body assembly (some
vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the
throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps
for PCV, EGR, EVAP and miscellaneous control signals (some vehicles only). 5. PCV air return (if
applicable). 6. A throttle body-mounted TP sensor. 7. A sealant/coating on the throttle bore and
throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These
throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal
advising not to clean.
8. A non-adjustable stop screw for close plate idle air flow.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Page 5113
Throttle Body: Service and Repair
THROTTLE BODY
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or
near any fuel-related components. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
CAUTION: The throttle body bore and plate area have a special coating and cannot be cleaned.
1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Disconnect the
electronic throttle control electrical connector. 4. Disconnect the throttle position (TP) sensor
electrical connector. 5. Remove the 4 bolts and the throttle body assembly.
- Discard the throttle body O-ring seal.
Installation
1. Using a new O-ring seal, install the throttle body and tighten the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).
- Stage 2: Tighten an additional 90 degrees.
2. Connect the throttle position (TP) sensor electrical connector. 3. Connect the electronic throttle
control electrical connector. 4. Install the air cleaner assembly. 5. Connect the battery ground
cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05
> Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05
> Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 5122
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: >
05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 5128
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 5129
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Page 5130
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 5133
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 5134
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Description and Operation
Variable Induction Control Actuator: Description and Operation
INTAKE MANIFOLD TUNING VALVE (IMTV)
Intake Manifold Tuning Valve (IMTV)
WARNING: Substantial opening and closing torque is applied by this system. To prevent Injury, be
careful to keep fingers away from lever mechanisms when actuated.
The IMTV is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator
controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with
this system to indicate shutter position.
The motorized IMTV unit is not energized below approximately 2,600 RPM. The shutter is in the
closed position not allowing airflow blend to occur in the intake manifold. Above approximately
2,600 RPM the motorized unit is energized. The motorized unit is commanded on by the PCM
initially at a 100 percent duty cycle to move the shutter to the open position, and then falling to
approximately 50 percent to continue to hold the shutter open.
1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV 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 IMTV. 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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Description and Operation > Page 5139
Variable Induction Control Actuator: Service and Repair
CHARGE MOTION CONTROL VALVE (CMCV)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the charge motion control valve (CMCV) RH and LH
rods from the intake manifold. 3. Remove the stud bolt, the 2 bolts and the CMCV.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Valve > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Number One Cylinder: Locations
Item ......................................................................................................................................................
............................................................ Specification
Firing order...........................................................................................................................................
......................................................... 1-3-7-2-6-5-4-8
Eight separate ignition coils:
- are mounted directly above each spark plug.
- are controlled by the powertrain control module (PCM) for correct firing sequence.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor 1 > Page 5156
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 5157
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 5158
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 5162
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 5163
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 5164
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips
Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips
TSB 05-22-8
11/14/05
WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE
MISFIRE OR ROUGH RUNNING
FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005
Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006
E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006
Escape 2002-2005 Explorer 2005-2006 Escape Hybrid
LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS
1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego
2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 04-16-01 to update the vehicle applications and model years.
NOTE
FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs
RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED.
ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS
Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition
problems (be sure to rule out coil primary circuit issues). Once the above steps have been
completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure
outlined in this TSB can isolate the difference between a coil or spark plug problem.
SERVICE PROCEDURE
The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and
help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through
1-800-ROTUNDA.
The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire
diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not
random misfires. Random misfires have a different root cause and are not covered by this TSB.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5169
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5170
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5171
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5172
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5173
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5174
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 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 5175
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5178
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5179
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5180
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5181
Ignition Coil: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5182
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5183
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5184
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 5185
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil On Plug (COP)
Ignition Coil: Description and Operation Coil On Plug (COP)
COIL ON PLUG (COP)
The COP ignition operates similar to standard coil pack ignition except each plug has one coil per
plug. COP has 3 different modes of operation: engine crank, engine running, and CMP Failure
Mode Effects Management (FMEM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil On Plug (COP) > Page 5188
Ignition Coil: Description and Operation Coil Pack
COIL PACK
Horizontal Connector 6-Tower Coil Pack
Series 5 6-Tower Coil Pack
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil On Plug (COP) > Page 5189
Four-Tower Coil Packs
The PCM provides a grounding switch for the coil primary circuit. When the switch is closed,
voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil.
The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the
secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark
plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next
time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine
firing order.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Page 5190
Ignition Coil: Service and Repair
IGNITION COIL-ON-PLUG
Engine Ignition - RH
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Page 5191
Engine Ignition - LH
Exploded View
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connector. 3.
Remove the bolt and the ignition coil.
- Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
- To install, tighten to 6 Nm (53 lb-in).
4. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that
there is no damage to the tip of the boot.
To install, reverse the removal procedure. Apply a light coat of dielectric compound to the inside of the ignition coil boots.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Knock Sensor 1 > Page 5197
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Page 5198
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Page 5199
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 5206
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 5207
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
F-150 Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No.
1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the
sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to
select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or
circuit. DTC P0340 is associated with this sensor.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC
P0345 is associated with this sensor and it is referred to as CMP2.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150
4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle
applications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 5208
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor
electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 5212
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 5213
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Three Different Types Of Crankshaft Position (CKP) Sensors
The CKP sensor is a magnetic transducer mounted on the engine block or timing cover and is
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the PCM The trigger wheel has a
total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed
information to the PCM. By monitoring the missing tooth, the PCM uses the CKP signal to
synchronize the ignition system and track the rotation of the crankshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 5214
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5.
Remove the 3 bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and
the CKP sensor. Discard the O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the new O-ring seal with clean engine oil prior to installation.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5220
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5221
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations
View 151-5 (Engine, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Knock Sensor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 5227
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Page 5228
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Page 5229
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
Removal and Installation
1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3.
Remove the 2 bolts and the 2 knock sensors.
- To install, tighten to 20 Nm (15 lb-ft).
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System - MIL ON/DTC P0300-P0308/P0316
Spark Plug: Customer Interest Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Customer Interest: > 08-25-4 > Dec > 08 > Ignition System - MIL ON/DTC P0300-P0308/P0316 > Page
5238
BASIC PART NO. CODE
12405 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
Spark Plug: Customer Interest Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's >
Page 5243
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's >
Page 5244
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Customer Interest: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough Idle/Long Crank/Misfire/DTC's >
Page 5245
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-25-4 > Dec > 08 > Ignition System - MIL ON/DTC
P0300-P0308/P0316
Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/DTC P0300-P0308/P0316
TSB 08-25-4
5.4L 3V WITH PO3OX AND/OR P0316 ACCOMPANIED BY SPARK KNOCK
FORD: 2004-2005 F-150 2005 Expedition, F-250, F-350
LINCOLN: 2005 Navigator
This article supersedes TSB 06-3-3 to update the Service Procedure and Part List.
ISSUE Some 2004-2005 F-150 and 2005 F-250, F-350, Expedition and Navigator vehicles
equipped with a 5.4L 3V engine, may exhibit the malfunction indicator lamp (MIL) on with misfire
diagnostic trouble codes (DTCs) P0300 through P0308 and/or P0316, and a spark knock.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
It may be necessary to replace the long or short block if damaged, and/or install latest level spark
plugs. Refer to the following:
1. Isolate the engine bank causing the misfire I engine knock using diagnostic trouble codes and/or
stethoscope.
2. De-power each cylinder individually on affected bank(s), one by one.
a. If noise disappears when any cylinder(s) are de-powered, proceed to Step 3 for those cylinders.
b. If noise does not disappear, use power balance test to isolate affected cylinders and proceed to
Step 3.
3. Perform cylinder leak down / compression test and/or use a borescope to check isolated
cylinders for damage (scuffed cylinder bore walls).
a. If engine damage is confirmed, replace the long or short block assembly under the provisions of
the latest edition of the Powertrain Reference Guide. Be sure the latest level spark plugs are
installed.
NOTE
THE LATEST LEVEL PLUG WILL BE MARKED WITH (PZT 14F) ON THE PORCELAIN
INSULATOR.
b. If no engine damage is found, be sure the latest level spark plugs are installed.
4. If the misfire / knock condition is still present further diagnostics may be required to determine
other sources of misfire, such as fuel injection monitoring or coil integrity checks with Integrated
Diagnostic System (IDS) diagnostic equipment.
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
MT082504 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-25-4 > Dec > 08 > Ignition System - MIL ON/DTC
P0300-P0308/P0316 > Page 5251
BASIC PART NO. CODE
12405 42
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5256
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5257
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5258
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5259
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5260
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5261
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5262
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5263
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
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Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5264
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
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Removal Instructions > Page 5265
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug
Removal Instructions > Page 5266
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's
Spark Plug: All Technical Service Bulletins Fuel System - MIL ON/Rough Idle/Long
Crank/Misfire/DTC's
TSB 05-13-4
07/11/05
HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE - MIL - DTCS P0300
THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
FORD: 2005 Expedition, F-150, F-Super Duty
ISSUE Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the
malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon
fouled or wet spark plugs.
The following diagnostic trouble codes (DTCs) may be present:
^ P0300 through P0308 (Random and or Specific Cylinder Misfire)
^ P0316 (Misfire detected on startup in first 1000 revolutions)
^ P0171 (System too lean-bank 1)
^ P0174 (System too lean-bank 2)
^ P0172 (System too rich-bank 1)
^ P0175 (System too rich-bank 2)
^ P2195 (02 Sensor signal biased/stuck lean (H02511))
^ P2197 (02 Sensor signal biased/stuck lean (H02521))
^ P2196 (02 Sensor signal biased/stuck rich (H02511))
^ P2198 (02 Sensor stuck biased/stuck rich (H02521))
ACTION Confirm if an intermittent injector concern is causing these symptoms using the following
Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the
injector(s) causing the concern and any spark plugs that may have become fouled as a result.
LINCOLN: 2005 Navigator
SERVICE PROCEDURE
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS
WARNING MAY RESULT IN PERSONAL INJURY.
CAUTION
PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR
THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE
OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB.
DO NOT ATTEMPT TO START OR CRANK THE ENGINE.
CAUTION
FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL
ENGINE DAMAGE WHILE TESTING
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 5271
THE IGNITION AND FUEL SYSTEMS WITH WDS.
SERVICE PROCEDURE 1:
1. Retrieve DTCs and record on repair order.
2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 3.
3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 4.
b. If Power Balance does not indicate a weak cylinder proceed to Step 5.
4. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 3.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair. Do not continue with this TSB.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
5. Run ignition tests with WDS.
a. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
b. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness
and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON
CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.
7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with
two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
8. Change oil and filter and clear DTCs. Proceed to Step 9.
9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of
10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated
exhaust oxygen sensor (H025) switching rates, to determine catalyst condition. Normal switching
frequency of the post-catalyst H025 should be very slow with reduced amplitude as compared to
the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED, "Catalyst
Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency monitor. Follow
Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.
SERVICE PROCEDURE 2:
NOTE
ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE
BEGINNING OF THIS TSB.
1. Retrieve DTCs and record on repair order.
2. Remove all spark plugs to determine if fuel is present in cylinder(s).
a. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected
cylinders. Proceed to Step 2b or 2c.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 5272
b. If no fuel is present leave spark plugs out and proceed to Step 4.
WARNING
PERFORM STEP 2C IN A WELL VENTILATE AREA AWAY FROM ALL IGNITION SOURCES.
HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO
FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.
c. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the
engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective
catch rag to remove any remaining fuel. Proceed to Step 3.
3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to
re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector
Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a
wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.
NOTE
IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE
INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S)
ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.
5. Replace the spark plug(s) that were fouled. Proceed to Step 6.
NOTE
IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005,
CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS
MARKED WITH "PZT 1F" ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE
THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK
PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.
6. Change the engine oil and filter. Proceed to Step 7.
NOTE
EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN
STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO
REMAINING IGNITION OR BASE ENGINE ISSUES.
7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc),
repair as necessary following normal repair procedures. Proceed to Step 8.
8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
a. If Power Balance indicates a weak cylinder proceed to Step 9.
b. If Power Balance does not indicate a weak cylinder proceed to Step 10.
9. Perform a Relative Compression test with WDS to determine if a base engine concern is
contributing to the weak cylinder(s) identified in Step 8.
a. If Relative Compression test indicates a low cylinder, confirm base engine concern by
performing a dry compression test using a compression gauge with all plugs removed and battery
condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics
for base engine repair.
b. If Relative Compression test or dry compression test do not show any issues, proceed to Step
10.
10. Run ignition tests with WDS.
a. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to
Step 11.
b. If ignition test does not indicate any issues, proceed to Step 11.
11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for
a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front
and rear heated exhaust oxygen sensor (H025) switching rates, to determine catalyst condition.
Normal switching frequency of the post-catalyst H025 should be very slow with reduced amplitude
as compared to the switching frequency and amplitude of the pre-catalyst H025. Refer to PC/ED,
"Catalyst Efficiency Monitor and Exhaust Systems" for an overview of the catalyst efficiency
monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if
necessary.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > 05-13-4 > Jul > 05 > Fuel System - MIL ON/Rough
Idle/Long Crank/Misfire/DTC's > Page 5273
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9F593 69
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions
Spark Plug: All Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5279
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5280
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5281
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5282
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5283
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5284
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5285
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5286
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5287
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5288
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Spark Plug: > 08-7-6 > Apr > 08 > Ignition System - Spark Plug Removal
Instructions > Page 5289
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap
Spark Plug: Specifications Gap
Spark Plug Gap ...................................................................................................................................
.................................0.040 - 0.50 in (1.02 - 1.27 mm)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap > Page 5292
Spark Plug: Specifications Torque
Spark Plug Torque ...............................................................................................................................
.........................................................34 Nm (25 ft-lb)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 5293
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
.................................................................... PZT-2FE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 PLUGS
Engine Ignition - RH
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Removal and Installation > Page 5296
Engine Ignition - LH
Exploded View
Removal and Installation
1. Remove the ignition coil-on-plug.
2. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Removal and Installation > Page 5297
Spark Plug: Service and Repair Spark Plug-Inspection
Spark Plug-Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or wont or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Removal and Installation > Page 5298
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a Heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Service and Repair
Pressure Regulating Solenoid: Service and Repair
Electronic Pressure Control (EPC) Solenoid
Special Tool(s)
Removal
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the
transmission fluid pan and filter.
3. Disconnect the molded lead frame from the solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the Torque Converter Clutch (TCC).
3 Disconnect the Electronic Pressure Control (EPC) solenoid.
4 Disconnect the bulkhead interconnector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Service and Repair > Page 5305
4. Remove the Electronic Pressure Control (EPC) solenoid.
1 Remove the EPC solenoid bolt.
2 Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
1 Install the EPC solenoid.
2 Install the EPC solenoid bolt.
2. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and
not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a
good contact, install a new lead frame.
3. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the
connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in
place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make
sure that the terminals pass fully through the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Service and Repair > Page 5306
connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the
connector in place. Make sure that the terminals pass fully through the connector slots.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair
Shift Indicator: Service and Repair
SELECTOR LEVER INDICATOR BULB
Removal and Installation
1. Push down the selector lever boot.
2. Push down the selector lever collar.
3. Remove the selector lever knob screw.
- Remove the selector lever knob.
4. Detach the selector lever indicator bezel.
- Disconnect the electrical connector.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service
and Repair
Control Module: Service and Repair
Four-Wheel Drive (4WD) Control Module
Removal and Installation
NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module
(PCM) and is not serviced separately.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Locations
Four Wheel Drive Selector Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Locations > Page 5320
View 151-1 (Engine Compartment)
The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1
located in the engine compartment. LH side, front.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Transfer Case Low to High Relay > Page 5323
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Testing and Inspection > Transfer Case Low to High Relay
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Testing and Inspection > Transfer Case Low to High Relay > Page 5326
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Testing and Inspection > Transfer Case Low to High Relay > Page 5327
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Testing and Inspection > Transfer Case Low to High Relay > Page 5328
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description
and Operation
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations >
Page 5337
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive. The operator of the vehicle controls. the position of the TCS.
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch
in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Service and Repair > Transmission Control (TC) Switch - Column Shift
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift
Transmission Control (TC) Switch - Column Shift
Removal and Installation
NOTE: The Transmission Control (TC) switch is not replaceable. If a new TC switch is required,
install a new transmission selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5343
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift
Transmission Control (TC) Switch - Floor Shift
Removal and Installation
NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a
new selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5347
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5348
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5349
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5350
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5351
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Output Shaft Speed (OSS) Sensor
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Output Shaft Speed (OSS) Sensor > Page 5356
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5359
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5360
Transmission Speed Sensor: Service and Repair
Speed Sensors
NOTE: Only remove the affected sensor.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5365
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5366
Four Wheel Drive Selector Switch: Description and Operation
FOUR-WHEEL DRIVE (4WD) MODE SWITCH
Typical 4WD Switch
The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to
adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 06-13-9 > Jul > 06 > Engine Controls - Hard Start/MIL
ON/Multiple DTC's Set
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard Start/MIL
ON/Multiple DTC's Set
TSB 06-13-9
07/10/06
HARD START, LOW POWER AT 3500 RPM, MIL ON P0340, P0344, P0172, P0175 AND
EXPEDITION ONLY - IDLES TOO FAST COLD
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-4-15 to update the vehicle model years.
ISSUE Some 2005-2006 Expedition/Navigators may exhibit a hard start during multiple restart
attempts or during hot soak restart attempts and / or the malfunction indicator lamp (MIL) on with
diagnostic trouble codes (DTCs) P0340, P0344, P0172, and / or P0175 and / or a reduction in
power between 3500 and 4500 RPM during wide open throttle (WOT) application. Some customers
may describe the condition as feeling like the transmission is slipping, a lack of transmission upshift
or a hesitation. 2005-2006 Expedition (only) may also exhibit a higher than normal idle on cold
start.
ACTION Follow normal diagnostics for the vehicle symptom(s) to determine if there is an actual
physical issue with the fuel / ignition / exhaust systems and / or base engine causing the
symptom(s). If no issues are found during normal diagnostics and the symptoms still occur,
reprogram the powertrain control module (PCM) to the latest calibration using IDS Release B43.4
or later. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
061309A 2005-2006 0.4 Hr.
Expedition/Navigator 5.4L 3V: Check Diagnostic Trouble Codes And Reprogram The Powertrain
Control Module (Do Not Use With 12650D, 12650D84)
MT061309 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough
Idle Condition
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Cold Start Rough
Idle Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough
Idle Condition > Page 5379
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-23-1 > Nov > 05 > Engine Controls - MIL ON/DTC
P0351-P0358/Delayed Shifts
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC
P0351-P0358/Delayed Shifts
TSB 05-23-1
11/28/05
MIL ON WITH DTC P0351-P0358 - LACK OF UPSHIFT
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-21-15 to update the vehicle model years.
ISSUE Some 2005-2006 Expedition vehicles built before 9/29/2005 and Navigator vehicles built
before 10/19/2005 may exhibit any/all of the following symptoms:
^ Malfunction indicator lamp on (MIL) with diagnostic trouble codes (DTCs) P0351-P0358 and no
drivability symptoms
^ (Navigator only) Delayed 1-2 shifts or lack of upshift, especially at low speeds with no DTCs. This
condition may be due to the driver resting his/her foot on the brake pedal while accelerating
ACTION Reprogram the powertrain control module (PCM) to the latest calibration using WDS
release B39.9 and higher or B40.1 and higher. This new calibration is not included in the B40 CD.
Calibration files may also be obtained at the website.
NOTE
DO NOT PERFORM THIS TSB FOR DTC P0351-0358 IF DRIVEABILITY SYMPTOMS ARE
PRESENT. FOLLOW NORMAL DIAGNOSTICS INSTEAD.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
052301A 2005-2006 0.4 Hr
Expedition/Navigator: Check For Diagnostic Trouble Codes And Reprogram The Powertrain
Control Module (Do Not Use With 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's
P2106 and P2135 Set
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's
P2106 and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's
P2106 and P2135 Set > Page 5388
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information
> Technical Service Bulletins > Customer Interest: > 05-6-3 > Apr > 05 > Engine Controls - MIL ON/DTC's P061B & P2106
Set
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's
P061B & P2106 Set
TSB 05-6-3
04/04/05
MIL ON WITH DTC P061B AND P2106 AFTER COLD START AND RAPID TRANSMISSION
GEAR ENGAGEMENT - VEHICLES BUILT BEFORE 1/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigators equipped with the 5.4L 3-valve engine, built before
1/24/2005, may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC)
P061B and/or P2106. This condition may occur during a cold start combined with a rapid
transmission gear engagement.
ACTION Reprogram the powertrain control module (PCM) to the latest calibration level using WDS
release B36.2 or higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
050603A 2005 Expedition/Navigator 0.4 Hr.
Check For Diagnostic Trouble Codes And Reprogram Powertrain Control Module (Do Not Use With
12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
06-13-9 > Jul > 06 > Engine Controls - Hard Start/MIL ON/Multiple DTC's Set
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard
Start/MIL ON/Multiple DTC's Set
TSB 06-13-9
07/10/06
HARD START, LOW POWER AT 3500 RPM, MIL ON P0340, P0344, P0172, P0175 AND
EXPEDITION ONLY - IDLES TOO FAST COLD
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-4-15 to update the vehicle model years.
ISSUE Some 2005-2006 Expedition/Navigators may exhibit a hard start during multiple restart
attempts or during hot soak restart attempts and / or the malfunction indicator lamp (MIL) on with
diagnostic trouble codes (DTCs) P0340, P0344, P0172, and / or P0175 and / or a reduction in
power between 3500 and 4500 RPM during wide open throttle (WOT) application. Some customers
may describe the condition as feeling like the transmission is slipping, a lack of transmission upshift
or a hesitation. 2005-2006 Expedition (only) may also exhibit a higher than normal idle on cold
start.
ACTION Follow normal diagnostics for the vehicle symptom(s) to determine if there is an actual
physical issue with the fuel / ignition / exhaust systems and / or base engine causing the
symptom(s). If no issues are found during normal diagnostics and the symptoms still occur,
reprogram the powertrain control module (PCM) to the latest calibration using IDS Release B43.4
or later. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
061309A 2005-2006 0.4 Hr.
Expedition/Navigator 5.4L 3V: Check Diagnostic Trouble Codes And Reprogram The Powertrain
Control Module (Do Not Use With 12650D, 12650D84)
MT061309 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Cold
Start Rough Idle Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 5402
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
05-23-1 > Nov > 05 > Engine Controls - MIL ON/DTC P0351-P0358/Delayed Shifts
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC P0351-P0358/Delayed Shifts
TSB 05-23-1
11/28/05
MIL ON WITH DTC P0351-P0358 - LACK OF UPSHIFT
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-21-15 to update the vehicle model years.
ISSUE Some 2005-2006 Expedition vehicles built before 9/29/2005 and Navigator vehicles built
before 10/19/2005 may exhibit any/all of the following symptoms:
^ Malfunction indicator lamp on (MIL) with diagnostic trouble codes (DTCs) P0351-P0358 and no
drivability symptoms
^ (Navigator only) Delayed 1-2 shifts or lack of upshift, especially at low speeds with no DTCs. This
condition may be due to the driver resting his/her foot on the brake pedal while accelerating
ACTION Reprogram the powertrain control module (PCM) to the latest calibration using WDS
release B39.9 and higher or B40.1 and higher. This new calibration is not included in the B40 CD.
Calibration files may also be obtained at the website.
NOTE
DO NOT PERFORM THIS TSB FOR DTC P0351-0358 IF DRIVEABILITY SYMPTOMS ARE
PRESENT. FOLLOW NORMAL DIAGNOSTICS INSTEAD.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
052301A 2005-2006 0.4 Hr
Expedition/Navigator: Check For Diagnostic Trouble Codes And Reprogram The Powertrain
Control Module (Do Not Use With 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC's P2106 and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 5411
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-6-3 >
Apr > 05 > Engine Controls - MIL ON/DTC's P061B & P2106 Set
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC's P061B & P2106 Set
TSB 05-6-3
04/04/05
MIL ON WITH DTC P061B AND P2106 AFTER COLD START AND RAPID TRANSMISSION
GEAR ENGAGEMENT - VEHICLES BUILT BEFORE 1/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigators equipped with the 5.4L 3-valve engine, built before
1/24/2005, may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC)
P061B and/or P2106. This condition may occur during a cold start combined with a rapid
transmission gear engagement.
ACTION Reprogram the powertrain control module (PCM) to the latest calibration level using WDS
release B36.2 or higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
050603A 2005 Expedition/Navigator 0.4 Hr.
Check For Diagnostic Trouble Codes And Reprogram Powertrain Control Module (Do Not Use With
12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 5420
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 5 (2005))
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 5421
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 5 (2005))
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 5 (2005))
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 5427
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 5 (2005))
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 5428
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 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair
Pressure Regulating Solenoid: Service and Repair
Electronic Pressure Control (EPC) Solenoid
Special Tool(s)
Removal
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the
transmission fluid pan and filter.
3. Disconnect the molded lead frame from the solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the Torque Converter Clutch (TCC).
3 Disconnect the Electronic Pressure Control (EPC) solenoid.
4 Disconnect the bulkhead interconnector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page
5435
4. Remove the Electronic Pressure Control (EPC) solenoid.
1 Remove the EPC solenoid bolt.
2 Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
1 Install the EPC solenoid.
2 Install the EPC solenoid bolt.
2. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and
not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a
good contact, install a new lead frame.
3. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the
connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in
place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make
sure that the terminals pass fully through the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page
5436
connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the
connector in place. Make sure that the terminals pass fully through the connector slots.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair
Pressure Regulating Solenoid: Service and Repair
Electronic Pressure Control (EPC) Solenoid
Special Tool(s)
Removal
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the
transmission fluid pan and filter.
3. Disconnect the molded lead frame from the solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the Torque Converter Clutch (TCC).
3 Disconnect the Electronic Pressure Control (EPC) solenoid.
4 Disconnect the bulkhead interconnector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5442
4. Remove the Electronic Pressure Control (EPC) solenoid.
1 Remove the EPC solenoid bolt.
2 Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
1 Install the EPC solenoid.
2 Install the EPC solenoid bolt.
2. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and
not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a
good contact, install a new lead frame.
3. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the
connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in
place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make
sure that the terminals pass fully through the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5443
connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the
connector in place. Make sure that the terminals pass fully through the connector slots.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > 1-2 Accumulator
Accumulator: Service and Repair 1-2 Accumulator
1-2 Accumulator
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the
transmission fluid pan and filter.
3. Compress the 1-2 accumulator piston and remove the accumulator piston retaining ring.
4. Remove the 1-2 shift accumulator assembly.
1 Remove the 1-2 accumulator cover.
2 Remove the 1-2 accumulator inner and outer springs.
3 Remove the 1-2 accumulator piston.
4 Remove the 1-2 accumulator upper spring.
Installation
1. Install the 1-2 shift accumulator assembly.
1 Install the 1-2 accumulator upper spring.
2 Install the 1-2 accumulator piston.
3 Install the 1-2 accumulator inner and outer springs.
4 Install the 1-2 accumulator cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > 1-2 Accumulator > Page 5448
2. Compress the 1-2 accumulator piston and remove the accumulator piston retaining ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T >
Component Information > Service and Repair > 1-2 Accumulator > Page 5449
Accumulator: Service and Repair 2-3 Accumulator
2-3 Accumulator
Removal
1. Remove the main control valve body.
2. Remove the 2-3 accumulator piston retainer.
3. Remove the accumulator piston and spring.
Installation
1. Install the 2-3 accumulator assembly.
1 Install the accumulator piston.
2 Install the accumulator piston spring.
3 Install the accumulator spring retainer.
2. Install the main control valve body.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Reverse Servo Assembly
Band Apply Servo: Service and Repair Reverse Servo Assembly
Reverse Servo Assembly
Special Tool(s)
Removal
1. Remove the main control valve body.
2. Using the special tool, remove the reverse band servo retaining ring.
1 Compress the servo spring.
2 Remove the reverse band servo retaining ring.
3. Remove the reverse servo assembly.
1 Remove the reverse band servo cover.
2 Remove the reverse band servo piston and rod.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Reverse Servo Assembly > Page 5454
3 Remove the reverse band servo spring.
Installation
NOTE: This is not an ordinary installation procedure and does not compensate for band wear.
1. NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
Install the reverse servo return spring and piston. ^
Do not install the piston cover.
2. Install the special tool and tighten the band apply bolt.
3. Attach the special tool to the transmission.
^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial
indicator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Reverse Servo Assembly > Page 5455
4. Loosen the bolt until the piston stops against the tool.
5. Verify that the amount of piston travel on the dial indicator is within specification.
6. If piston travel is not within specification, select and install the correct servo piston assembly to
bring the servo piston travel within specification.
1 One groove
2 Two groove
3 Three groove
7. Remove the dial indicator and servo selection tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Reverse Servo Assembly > Page 5456
8. Install the correct reverse servo assembly.
1 Install the reverse band servo spring.
2 Install the reverse band servo piston and rod.
3 Install the reverse band servo cover.
9. Using the special tool, install the reverse servo retaining ring.
1 Compress the servo spring.
2 Install the reverse band servo retaining ring.
10. Install the main control valve body.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Reverse Servo Assembly > Page 5457
Band Apply Servo: Service and Repair Overdrive Servo
Overdrive Servo
Special Tool(s)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the main control valve body.
3. NOTE: If the tool is not available, extreme care must be taken. Spring pressure will force
overdrive servo piston assembly out of case. Case bore
damage may result from trying to pry on overdrive servo internal retaining ring.
Using the special tool, compress the servo spring to remove the overdrive servo retaining ring.
4. Remove the overdrive servo piston and return spring.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Reverse Servo Assembly > Page 5458
1. Install the overdrive servo piston assembly.
1 Install the overdrive servo piston return spring.
2 Install the overdrive servo piston assembly.
2. Use the special tool to install the overdrive servo piston retaining ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
.......................................................... 13.1L (13.9 Qt)
Note: Approximate capacity specifications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 5466
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Fluid Type ............................................................................................................................................
............................................... MERCON XT-2-QDX
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26
Fluid - A/T: Service and Repair Automatic Transmission - 6HP26
Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler - Backflushing and Cleaning
Material
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the cooler lines and install a new cooler before placing the transmission in use.
1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is
indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines.
3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting
them to the cleaner.
Connect the cleaner pressure and return lines appropriately. 1
Connect the pressure line to the fluid cooler inlet tube.
2 Connect the return line to the fluid cooler outlet tube.
3 Place the outlet end of the return line in the fluid tank reservoir.
4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system.
Switch the fluid pumps on. Allow the fluid to circulate a minimum of five minutes.
5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7.
Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove
the rubber hoses from the fluid cooler tubes.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Material
Drain
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5469
2. Remove the fluid pan drain plug and allow the fluid to drain.
Refill
1. Install the fluid pan drain plug.
^ Tighten to 8 Nm (71 inch lbs.).
2. Remove the fluid fill plug located on the RH rear side of the case, near the transmission
electrical connector.
3. CAUTION: The use of any other transmission fluid than specified can result in the transmission
failing to operate in a normal manner or
transmission failure.
Fill the transmission. ^
Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid
fill hole. Stop when the fluid runs out of the bottom of the hole.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5470
4. Install the fluid fill plug located on the RH rear side of the case, near the transmission electrical
connector. 5. Start the engine. Move the transmission range selector lever through all the gear
ranges, checking for engagements. 6. With the engine idling (600 - 750 rpm) in PARK and the
transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the
transmission fluid level.
7. If more fluid is needed, remove the fluid fill plug on the side of the case and fill with clean
automatic transmission fluid until the fluid runs out of
the bottom of the hole.
Transmission Fluid Level Check
Transmission Fluid Level Check
Fluid Level Check
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate
reading.
NOTE: The transmission fluid temperature must not be allowed to exceed 50°C (122°F) when
checking the fluid level. The fluid temperature should be between 30°C - 50°C (86°F - 122°F)
closer to 50°C (122°F) when checking the fluid level.
This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the
transmission operation and can result in transmission failure. Under normal circumstances, the fluid
level should not be checked during normal maintenance. If the transmission starts to slip, shifts
slowly or shows signs of fluid leaking, the fluid level should be checked.
1. With the transmission in P (PARK), the engine at idle (600 - 750 rpm) and foot pressed on the
brake, move the range selector lever through each
gear and allow engagement of each gear. Place the transmission range selector lever in the P
position.
2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the fluid fill plug
located on the side of the transmission case. 4. Partially add fluid until fluid starts to come out. Wait
until the fluid stops or just drips from the hole. 5. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.).
High Fluid Level
CAUTION: A fluid level that is too high can cause the fluid to become aerated due to the churning
action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid
from the vent tube and Possible transmission failure.
If an overfill reading is indicated, drain and refill the transmission.
Low Fluid Level
A low fluid level can result in poor transmission engagement, slipping or failure. This may also
indicate a leak in one of the transmission seals or
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5471
gaskets.
Adding Fluid
CAUTION: The use of any other type of transmission fluid than specified can result in transmission
failure.
If fluid must be added, add fluid in 0.5 liter (1/2 quart) increments through the fluid fill plug. Do not
overfill the fluid. For fluid type, refer to the specification chart.
Fluid Condition Check
1. Check the fluid level. 2. Remove the fluid fill plug and allow the fluid to drip onto a facial tissue
and examine the stain.
3. NOTE: The transmission fluid could be two different colors. The factory fill fluid is clear. The
replacement fluid is red.
Observe the color and the odor. The color under normal circumstances should be dark reddish or
clear, not black or have a burnt odor.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further
inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The
engine cooling system should also be inspected at this time. 6. If fluid contamination or
transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission
must be disassembled
and completely cleaned. This includes the torque converter and fluid cooler tubes. A new oil-to-air
cooler must be installed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5472
Fluid - A/T: Service and Repair Automatic Transmission - 4R70E/4R75E
Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
Material
1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The
use of these products could cause internal
transmission components to fail; this will effect the operation of the transmission.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to
make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush
equipment if flow is weak or contaminated.
2. If equipped, remove and discard the transmission fluid in-line filter. 3. To aid in attaching the
cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the
transmission end of the steel
transmission cooler lines as described below. ^
Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line).
^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the
outlet end of this hose in the tank reservoir.
4. Turn on the pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and
off will help dislodge contaminants in cooler
system).
5. Switch off the pump and disconnect the pressure hose from the transmission cooler return line.
6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler
return line) until all fluid is removed. 7. Remove the rubber return hose from the remaining steel
cooler line.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Special Tool(s)
Material
Draining, all vehicles using a suitable flush and fill machine
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5473
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for normal
or severe duty fluid maintenance.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to
change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid
cooler tube after the fluid cooler on the cooler return line. This will
help remove any foreign material trapped in the fluid coolers.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the
engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F),
check and adjust the transmission fluid
level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until
the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Draining, all vehicles not using a suitable flush and fill machine
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan. 4. Do not remove the fluid filter. It
is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Clean and inspect the transmission fluid pan, transmission fluid gasket and magnet. 6.
Thoroughly flush the cooler tubes.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5474
Refill
1. Position the magnet into the transmission fluid pan.
2. NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket. 1
Position the fluid pan with the gasket in place.
2 Install the bolts.
3. CAUTION: The use of any other transmission fluid can result in the transmission failing to
operate in a normal manner or transmission failure.
Fill the transmission. ^
Add 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the fluid filler
tube.
4. Start the engine. Move the transmission range selector lever through all the gear ranges,
checking for engagements. 5. With the engine running and the transmission at normal operating
temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid
level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until
the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Transmission Fluid Level Check
Transmission Fluid Level Check
CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the DO
NOT DRIVE mark or internal failure could result.
NOTE: If vehicle has been operated for an extended period of time at highway speeds, in city
traffic, in hot weather or when pulling a trailer, the fluid needs to cool down to obtain an accurate
reading.
NOTE: The fluid level reading on the indicator will differ from operating and ambient temperatures.
The correct reading should be within the normal operating temperature range.
Under normal circumstances, the fluid level should be checked during normal maintenance. If the
transmission starts to slip, shifts slowly or has signs of fluid leaking, the fluid level should be
checked.
1. With the transmission in (P) PARK, the engine at idle, foot pressed on the brake, move the range
selector lever through each gear and allow
engagement of each gear. Place the range selector lever in the PARK position.
2. Wipe the fluid level indicator cap and remove the indicator. 3. Wipe the indicator with a clean
cloth.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5475
4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator.
The fluid level should be within the normal operating temperature range.
High Fluid Level
A fluid level that is too high may cause the fluid to become aerated due to the churning action of
the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the
vent tube and Possible transmission malfunction and/or damage. If an overfill reading is indicated
drain and refill the transmission.
Low Fluid Level
A low fluid level could result in poor transmission engagement, slipping, malfunction and/or
damage. This could also indicate a leak in one of the transmission seals or gaskets.
Adding Fluid
CAUTION: The use of any type of transmission fluid other than specified could result in
transmission malfunction and/or damage.
If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not
overfill the fluid. For fluid type, refer to the General Specifications chart.
Fluid Condition Check
1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances
should be dark reddish, not brown or black or have a burnt odor. 3. Hold the fluid level indicator
over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If
evidence of solid material is found, the transmission fluid pan should be removed for further
inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The
engine cooling system should also be inspected at this time. 6. If fluid contamination or
transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission
must be disassembled
and completely cleaned. This includes the torque converter, coolers and cooler lines.
7. Carry out diagnostic checks and adjustments; refer to Diagnosis By Symptom.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter
Fluid Filter - A/T: Service and Repair Transmission Fluid In-Line Filter
Transmission Fluid In-Line Filter
Material
Transmission Fluid In-line Filter with a OTA cooler
NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^
If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a
new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If equipped, remove the bolts and the skid plate.
3. Remove the section of the rubber hose and steel line as illustrated.
^ Clean and de-burr the end of the steel line.
4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of
the ferrule nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5480
Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube.
Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the
connector.
5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of
fluid flow through the filter. The filter must
be installed in the fluid cooler return line with the red arrow on the filter pointing away from the
transmission fluid cooler and toward the transmission (the return line has fluid coming out of the
cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal
transmission damage.
CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater
than 60 degrees.
Using a suitable length of hose install the filter. Tighten the hose clamps.
6. Clean a section of the transmission fluid pan and install the sticker.
7. If equipped, install the skid plate and the bolts. 8. Fill the transmission with clean automatic
transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Transmission Fluid In-line Filter without a OTA cooler
NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^
If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a
new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5481
2. Remove the cooler tubes retainers.
3. Remove the section of the steel tube as illustrated.
^ Clean and de-burr the end of the steel tubes.
4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of
the ferrule nut.
Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes.
Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the
connector.
5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of
fluid flow through the filter. The filter must
be installed in the fluid cooler return line with the red arrow on the filter pointing away from the
transmission fluid cooler and toward the transmission (the return line has fluid coming out of the
cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal
transmission damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5482
CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater
than 60 degrees.
Using a suitable length of hose install the filter. Tighten the hose clamps.
6. Install one cooler tube retainer as illustrated.
7. Secure the cooler tubes together with a tie strap.
8. Clean a section of the transmission fluid pan and install the sticker. 9. Fill the transmission with
clean automatic transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5483
Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Material
Removal
CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use
of these products could cause internal transmission components to fail; this will effect the operation
of the transmission. Use of a fluid other than specified could result in transmission failure.
NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major
repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will need to be
removed for repair. The transmission fluid needs to be changed if evidence of fluid contamination is
found.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain transmission fluid.
^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the
bolts.
3. Remove the transmission fluid pan and transmission fluid pan gasket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5484
4. Pull down evenly and remove the transmission fluid filter and seal.
5. Clean and inspect the transmission fluid pan, gasket and magnet.
Installation
1. CAUTION: If installing a new filter and the seal remains in the main control bore, carefully use a
small screwdriver to remove the seal. Use care
not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
Install a new fluid filter and seal as required.
2. Position the pan magnet into the transmission fluid pan.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5485
3. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket. 1
Position the transmission fluid pan and gasket.
2 Install the transmission fluid pan bolts.
4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7 liters (5
quarts).
Fill the transmission to the correct level with clean automatic transmission fluid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With
Auxiliary Transmission Fluid Cooler
Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary Transmission Fluid Cooler
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the transmission fluid cooler tubes from the transmission.
3. Disconnect the transmission fluid cooler tubes from the thermostatic valve.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5490
4. Remove the transmission fluid cooler tube retainer from the front of the engine.
5. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
6. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
7. Remove the secondary latch from the upper transmission fluid cooler tube at the radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5491
8. Using the special tool, disconnect the upper transmission fluid cooler tube from the radiator.
9. Remove the secondary latch from the lower transmission fluid cooler tube at the radiator.
10. Using the special tool, disconnect the lower transmission fluid cooler tube from the radiator. 11.
Remove the transmission fluid cooler tubes from the vehicle.
Installation
1. Position the transmission fluid cooler tubes in the vehicle.
2. Connect the lower transmission fluid cooler tube to the radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5492
3. Install the secondary latch to the lower transmission fluid cooler tube at the radiator.
4. Connect the upper transmission fluid cooler tube to the radiator.
5. Install the secondary latch to the upper transmission fluid cooler tube at the radiator.
6. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5493
7. Install the transmission fluid cooler tube retainer to the front of the engine.
8. Connect the transmission fluid cooler tubes to the thermostatic valve.
9. Connect the transmission fluid cooler tubes to the transmission.
10. Fill the transmission with the specified type and quantity of transmission fluid. 11. Check for
leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5494
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 4R70E, 4R75E, Without
Auxiliary Transmission Fluid Cooler
Transmission Fluid Cooler Tubes - 4R70E, 4R75E, Without Auxiliary Transmission Fluid Cooler
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the transmission fluid cooler tubes from the transmission.
3. Disconnect the transmission fluid cooler tubes from the thermostatic valve.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5495
4. Remove the transmission fluid cooler tube retainer from the front of the engine.
5. Remove the secondary latch from the upper transmission fluid cooler tube at the radiator.
6. Using the special tool, disconnect the upper transmission fluid cooler tube from the radiator.
7. Remove the secondary latch from the lower transmission fluid cooler tube at the radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5496
8. Using the special tool, disconnect the lower transmission fluid cooler tube from the radiator. 9.
Remove the transmission fluid cooler tubes from the vehicle.
Installation
1. Position the transmission fluid cooler tubes in the vehicle.
2. Connect the lower transmission fluid cooler tube to the radiator.
3. Install the secondary latch to the lower transmission fluid cooler tube at the radiator.
4. Connect the upper transmission fluid cooler tube to the radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5497
5. Install the secondary latch to the upper transmission fluid cooler tube at the radiator.
6. Install the transmission fluid cooler tube retainer to the front of the engine.
7. Connect the transmission fluid cooler tubes to the thermostatic valve.
8. Connect the transmission fluid cooler tubes to the transmission. 9. Fill the transmission with the
specified type and quantity of transmission fluid.
10. Check for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5498
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 6HP26
Transmission Fluid Cooler Tubes - 6HP26
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Separate the fluid cooler lines.
3. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5499
4. Remove the transmission fluid cooler tube retainer from the front of the engine.
5. Remove the transmission fluid cooler tube rear support bracket from the side of the
transmission.
6. NOTE: The cooler tube band seals and backer rings may remain in the transmission case.
Carefully remove them from the case if retained.
Disconnect the transmission fluid cooler tubes from the transmission.
7. Disconnect the engine oil level sensor electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5500
8. If equipped, remove the RH bolt and nut for the front axle, lower the RH side of the axle.
9. Remove the four nuts, and lower the front sway bar.
10. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
11. Disconnect the secondary latch from the upper transmission fluid cooler connector at the
radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5501
12. Using the special tool, disconnect the upper transmission fluid cooler tube from the radiator.
13. Disconnect the secondary latch from the lower transmission fluid cooler connector at the
radiator.
14. Using the special tool, disconnect the lower transmission fluid cooler tube from the radiator. 15.
Remove the transmission fluid cooler tubes from the vehicle.
Installation
1. Position the transmission fluid cooler tubes in the vehicle.
2. Connect the lower transmission fluid cooler tube to the radiator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5502
3. Install the secondary latch to the lower transmission fluid cooler tube at the radiator.
4. Connect the upper transmission fluid cooler tube to the radiator.
5. Install the secondary latch to the upper transmission fluid cooler tube at the radiator.
6. NOTE: Inspect the case to make sure that the old band seals and backer rings are not stuck in
the case.
NOTE: Install new band seals and backer rings on the ends of the cooler lines prior to installing.
Install new seals on the transmission fluid cooler tubes. 1
Transmission fluid cooler tube.
2 Retainer plate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5503
3 Backer ring.
4 Band seal.
7. NOTE: Inspect the case to make sure that the old band seals and backer rings are not stuck in
the case.
NOTE: Install new band seals and backer rings on the ends of the cooler lines prior to installing.
Position the fluid cooler lines into the transmission, then install the bolt for the transmission cooler
line retainer.
8. Install the transmission fluid cooler tube retainer to the side of the transmission.
9. Install the transmission fluid cooler tube retainer to the front of the engine.
10. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5504
11. Position the sway bar in place and install the four nuts.
^ Tighten to 55 Nm (41 ft. lbs.).
12. If removed, position the axle and install the RH bolt and nut.
^ Tighten to 102 Nm (75 ft. lbs.).
13. Connect the engine oil level sensor electrical connector. 14. With the vehicle idling (600 - 750
rpm) in PARK, and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust
the
transmission fluid level.
15. Remove the fluid fill plug located on the RH rear side of the case near the transmission
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 4R70E, 4R75E, With Auxiliary
Transmission Fluid Cooler > Page 5505
16. CAUTION: The use of any other transmission fluid can result in the transmission failing to
operate in a normal manner or transmission failure.
Fill the transmission. ^
Add clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the
fluid runs out of the bottom of the hole.
17. Install the fluid fill plug. 18. Move the transmission range selector lever through all the gear
ranges, checking for engagements.
19. If more fluid is needed, start the engine. Remove the fluid fill plug on the side of the case, fill
with clean automatic transmission fluid until fluid
just starts to dribble out of the hole. Install the fill plug
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Automatic Transmission - 6HP26
Fluid Pan: Specifications Automatic Transmission - 6HP26
Transmission fluid pan bolts ................................................................................................................
............................................... 8 Nm (71 inch lbs.)
^ Tighten the bolts in a crisscross pattern.
Transmission fluid drain plug
..............................................................................................................................................................
8 Nm (71 inch lbs.) Transmission fluid fill plug ....................................................................................
................................................................................ 35 Nm (26 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Automatic Transmission - 6HP26 > Page 5510
Fluid Pan: Specifications Automatic Transmission - 4R70E/4R75E
Transmission fluid pan bolts ................................................................................................................
.................................................. 14 Nm (10 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter
Fluid Pan: Service and Repair Transmission Fluid In-Line Filter
Transmission Fluid In-Line Filter
Material
Transmission Fluid In-line Filter with a OTA cooler
NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^
If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a
new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If equipped, remove the bolts and the skid plate.
3. Remove the section of the rubber hose and steel line as illustrated.
^ Clean and de-burr the end of the steel line.
4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of
the ferrule nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5513
Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube.
Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the
connector.
5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of
fluid flow through the filter. The filter must
be installed in the fluid cooler return line with the red arrow on the filter pointing away from the
transmission fluid cooler and toward the transmission (the return line has fluid coming out of the
cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal
transmission damage.
CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater
than 60 degrees.
Using a suitable length of hose install the filter. Tighten the hose clamps.
6. Clean a section of the transmission fluid pan and install the sticker.
7. If equipped, install the skid plate and the bolts. 8. Fill the transmission with clean automatic
transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Transmission Fluid In-line Filter without a OTA cooler
NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^
If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a
new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line
transmission fluid filter that is supplied.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5514
2. Remove the cooler tubes retainers.
3. Remove the section of the steel tube as illustrated.
^ Clean and de-burr the end of the steel tubes.
4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of
the ferrule nut.
Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes.
Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the
connector.
5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of
fluid flow through the filter. The filter must
be installed in the fluid cooler return line with the red arrow on the filter pointing away from the
transmission fluid cooler and toward the transmission (the return line has fluid coming out of the
cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal
transmission damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5515
CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater
than 60 degrees.
Using a suitable length of hose install the filter. Tighten the hose clamps.
6. Install one cooler tube retainer as illustrated.
7. Secure the cooler tubes together with a tie strap.
8. Clean a section of the transmission fluid pan and install the sticker. 9. Fill the transmission with
clean automatic transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5516
Fluid Pan: Service and Repair Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Material
Removal
CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use
of these products could cause internal transmission components to fail; this will effect the operation
of the transmission. Use of a fluid other than specified could result in transmission failure.
NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major
repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will need to be
removed for repair. The transmission fluid needs to be changed if evidence of fluid contamination is
found.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Drain transmission fluid.
^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the
bolts.
3. Remove the transmission fluid pan and transmission fluid pan gasket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5517
4. Pull down evenly and remove the transmission fluid filter and seal.
5. Clean and inspect the transmission fluid pan, gasket and magnet.
Installation
1. CAUTION: If installing a new filter and the seal remains in the main control bore, carefully use a
small screwdriver to remove the seal. Use care
not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
Install a new fluid filter and seal as required.
2. Position the pan magnet into the transmission fluid pan.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5518
3. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket. 1
Position the transmission fluid pan and gasket.
2 Install the transmission fluid pan bolts.
4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7 liters (5
quarts).
Fill the transmission to the correct level with clean automatic transmission fluid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Shift Indicator > Component Information > Service and Repair
Shift Indicator: Service and Repair
SELECTOR LEVER INDICATOR BULB
Removal and Installation
1. Push down the selector lever boot.
2. Push down the selector lever collar.
3. Remove the selector lever knob screw.
- Remove the selector lever knob.
4. Detach the selector lever indicator bezel.
- Disconnect the electrical connector.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Locations > Page 5526
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Service and Repair
Pressure Regulating Solenoid: Service and Repair
Electronic Pressure Control (EPC) Solenoid
Special Tool(s)
Removal
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the
transmission fluid pan and filter.
3. Disconnect the molded lead frame from the solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the Torque Converter Clutch (TCC).
3 Disconnect the Electronic Pressure Control (EPC) solenoid.
4 Disconnect the bulkhead interconnector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Service and Repair > Page 5530
4. Remove the Electronic Pressure Control (EPC) solenoid.
1 Remove the EPC solenoid bolt.
2 Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
1 Install the EPC solenoid.
2 Install the EPC solenoid bolt.
2. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and
not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a
good contact, install a new lead frame.
3. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the
connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in
place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make
sure that the terminals pass fully through the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Service and Repair > Page 5531
connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the
connector in place. Make sure that the terminals pass fully through the connector slots.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26
Seals and Gaskets: Service and Repair Automatic Transmission - 6HP26
Output Shaft Seal
Output Shaft Seal
Special Tool(s)
Material
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
4x2 vehicles
2. Remove the rear driveshaft.
3. Remove and discard the output shaft flange nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5536
4. Remove the output shaft flange.
5. Remove the output shaft seal.
4x4 vehicles
6. Remove the transfer case.
7. Remove the eleven bolts and the extension housing.
8. Remove the output shaft seal.
Installation
4x2 vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5537
1. Position a new output shaft seal.
2. Using the special tool, install the output shaft seal.
3. Install the output shaft flange.
4. Install a new output shaft flange nut.
^ After installing the new nut, it must be staked at the slots to prevent it from coming loose.
^ Tighten to 120 Nm (89 ft. lbs.)
5. Install the rear driveshaft.
4x4 vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5538
6. Position the output shaft seal.
7. Using the special tool, install a new output shaft seal.
8. Install the extension housing and the 11 bolts. 9. Install the transfer case.
All vehicles
10. Start the engine. Move the transmission range selector lever through all the gear ranges,
checking for engagements. 11. With the engine idling (600 - 750 rpm) in PARK and the
transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the
transmission fluid level.
12. With the engine still running and the vehicle in PARK, remove the fluid fill plug.
^ The fill plug is located on the RH rear side of the case near the transmission electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5539
13. CAUTION: The use of any other transmission fluid than specified can result in the transmission
failing to operate in a normal manner or
transmission failure.
Fill the transmission. ^
Add clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the
fluid runs out of the bottom of the hole.
14. Install the fluid fill plug.
15. With the engine still running in PARK, check the fluid level. If more fluid is needed, remove the
fluid fill plug and fill with clean automatic
transmission fluid until the fluid runs out of the bottom of the hole.
16. Install the fluid fill plug.
Manual Control Lever Shaft and Seal
Manual Control Lever Shaft and Seal
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5540
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the shift cable end and remove the shift cable bracket bolts. Position the cable and
bracket aside.
3. Remove the transmission fluid pan drain plug and allow the fluid to drain.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5541
4. Install the transmission fluid pan drain plug.
^ Tighten to 8 Nm (71 inch lbs.)
5. NOTE: The transmission fluid pan, gasket, filter and magnets are serviced as a complete unit.
Remove the transmission fluid pan assembly.
6. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on
the connector.
7. Press the release tab and pull down on the bulkhead connector retainer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5542
8. With the release tab down, pull the outer shell of the bulkhead electrical connector.
9. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will
cause damage to the mechatronic unit.
Pull the outer shell of the bulkhead electrical connector out of the transmission.
10. Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly.
11. Remove the park rod actuating plate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5543
12. Remove the manual control lever.
1 Remove the roll pin.
2 Slide the manual control lever shaft out of the case.
3 Hold the spacer to keep it from falling out of the case.
4 Remove the manual valve inner lever and the park rod as an assembly.
13. Remove and discard the manual control lever seal.
Installation
1. Position a new manual control lever seal in place.
2. Using the special tool, install a new manual control lever shaft seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5544
3. Install the manual lever in the case.
1 Slide the manual lever in the case.
2 Position the spacer in place while sliding the manual lever into the spacer.
3 Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
4 Install the roll pin.
4. Position the park rod in place. Push down on the park pawl and position the park rod in place.
5. While holding the park rod down, install the park rod actuating plate.
6. Position the mechatronic assembly in place and loosely install the 10 bolts.
7. Tighten the mechatronic bolts in the sequence shown.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5545
8. Install new O-rings on the outer shell of the bulkhead electrical connector.
9. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will
cause damage to the mechatronic unit.
With the release tab down, push the outer shell of the bulkhead electrical connector into the
transmission.
10. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place.
11. Install the transmission fluid pan. Tighten the bolts in a crisscross pattern.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5546
12. Install the shift cable bracket bolts and connect the shift cable end.
13. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
14. Remove the fluid fill plug.
^ The fill plug is located on the RH rear side of the case near the transmission electrical connector.
15. CAUTION: The use of any other transmission fluid than specified can result in the transmission
failing to operate in a normal manner or
transmission failure.
Fill the transmission. ^
Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid
fill hole. Stop when the fluid runs out of the bottom of the hole.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5547
16. Install the fluid fill plug. 17. Start the engine. Move the transmission range selector lever
through all the gear ranges, checking for engagements. 18. With the engine idling (600 - 750 rpm)
in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the
transmission fluid level.
19. With the engine still running in PARK check the fluid level. If more fluid is needed, remove the
fluid fill plug on the side of the case and fill with
clean automatic transmission fluid until the fluid runs out of the bottom of the hole.
20. Install the fluid fill plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5548
Seals and Gaskets: Service and Repair Automatic Transmission - 4R70E/4R75E
Extension Housing Gasket
Extension Housing Gasket
Material
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
4x2 vehicles
2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original positions.
Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly.
3. Remove the rear driveshaft.
1 Remove the four bolts.
2 Remove the rear driveshaft.
4x4 vehicles
4. Remove the transfer case.
All vehicles
5. Use the high-lift jack to support the transmission.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5549
6. NOTE: RH shown, LH similar.
Remove the two bolts retaining the heat shield to the transmission support crossmember.
7. Loosen, but do not remove the transmission-to-crossmember nuts.
8. Remove the six crossmember-to-frame nuts and bolts (three on each side).
9. Remove the transmission mount-to-crossmember nuts and remove the crossmember.
5.4L engines
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5550
10. Remove the nut from the exhaust bracket.
11. Remove the two bolts, the rear transmission mount and the exhaust hanger. 12. Lower the
transmission to access the extension housing bolts.
13. NOTE: 4x2 shown, 4x4 similar.
Remove the extension housing and gasket. 1
Remove the nuts and bolts.
2 Remove the extension housing and gasket. Allow fluid to drain into suitable container.
Installation
All vehicles
1. NOTE: 4x2 shown, 4x4 similar.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5551
Install the extension housing and a new gasket. 1
Position the extension housing gasket and the extension housing.
2 Install the bolts and nuts.
2. Raise and position the transmission.
3. Position the exhaust hanger, the rear transmission insulator and install the bolts.
4. Install the exhaust bracket nut.
5. Position the crossmember and loosely install the transmission mount-to-crossmember nut.
6. NOTE: RH shown, LH similar.
Install the six crossmember-to-frame nuts and bolts (three on each side).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5552
7. Lower the transmission on the crossmember and tighten the rear mount nuts.
8. NOTE: 4x2 shown, 4x4 similar.
Remove the high-lift transmission jack.
9. Install the two bolts retaining the heat shield to the transmission support crossmember.
4x4 vehicles
10. Install the transfer case.
4x2 vehicles
11. NOTE: The output shaft and the driveshaft are a balanced assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5553
Install the driveshaft. ^
Align the yellow dots and position the driveshaft on the transmission.
12. Install the rear driveshaft.
1 Position the driveshaft.
2 Install the four bolts.
All vehicles
13. Lower the vehicle. 14. Fill the transmission with clean automatic transmission fluid.
^ Verify for correct operation.
^ Check for leaks.
Extension Housing Seal
Extension Housing Seal
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5554
2. NOTE: The output shaft and driveshaft are a balanced assembly.
Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly.
3. Remove the 4 driveshaft bolts.
4. Slide the driveshaft back enough to index-mark the driveshaft, the extension housing and the
output shaft. Separate the driveshaft from the
transmission.
5. Using the special tools, remove the extension housing seal.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5555
1. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the 6 o'clock
position.
Using the special tool, install a new extension housing seal.
2. NOTE: The output shaft and the driveshaft are a balanced assembly.
Install the driveshaft. ^
Align all the index marks and position the driveshaft on the transmission.
^ Install the driveshaft.
3. NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original
position that was marked during removal.
Install the 4 retaining bolts.
4. Check the level of the transmission fluid, add clean automatic transmission fluid as necessary.
Manual Control Lever Shaft and Seal
Manual Control Lever Shaft and Seal
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5556
Special Tool(s)
Removal and Installation
CAUTION: Use care not to damage the manual control lever shaft bore. The new seal can leak.
CAUTION: Discard the outer manual control lever nut.
NOTE: When removing the manual control lever shaft retaining pin, use a soft cloth to protect the
surface of the case.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. On 4x4 vehicles, remove the front driveshaft shield nuts and remove the shield.
3. NOTE: Index mark the front and rear flange.
NOTE: It is not necessary to remove the front driveshaft from the vehicle.
On 4x4 vehicles, index mark the front and rear flange, disconnect the front driveshaft and position
aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5557
4. Loosen, but do not remove the transmission fluid pan bolts and allow the fluid to drain. Once the
fluid has drained, remove the bolts.
5. Remove the transmission fluid pan and gasket.
6. Disconnect the digital Transmission Range (TR) electrical connector.
7. Disconnect the shift cable end.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5558
8. Remove the manual control lever.
1 Remove the manual control lever nut.
2 Remove the manual control lever.
9. Remove the digital TR sensor.
1 Remove the 2 retaining bolts.
2 Remove the digital TR sensor.
10. Remove the manual control valve detent lever spring.
1 Remove the manual control valve detent lever spring bolt.
2 Remove the manual control valve detent lever spring.
11. Remove the manual shaft retaining pin.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5559
12. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of
the case.
13. Remove the manual control lever shaft seal.
Installation
1. Using the special tool, install the manual control lever seal.
2. Install the manual valve detent lever into the manual valve.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5560
3. Install the manual control lever shaft.
1 Install the manual control lever shaft.
2 Install the inner manual control lever shaft and nut.
3 Install the manual valve detent lever spring bolt.
4. Install the manual valve detent lever spring.
1 Install the manual valve detent lever spring.
2 Install the manual valve detent lever spring bolt.
5. Install the digital TR sensor.
1 Install the digital TR sensor.
2 Loosely install the bolts.
6. NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5561
7. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the digital TR sensor bolts.
8. Install the manual control lever.
1 Position the manual control lever.
2 Install a new manual control lever nut.
9. Connect the shift cable end to the manual lever with the lever in the (D) position.
10. Instal the digital TR sensor electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5562
11. Position the pan magnet into the transmission fluid pan.
12. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket. 1
Position the transmission fluid pan gasket.
2 Position the transmission fluid pan.
13. Install the transmission fluid pan bolts.
14. On 4x4 vehicles, install the front driveshaft and align the index marks made during removal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5563
15. Install the front driveshaft shield and install the 2 nuts.
16. NOTE: Start by filling the transmission with 4.7 liters (5 quarts) of clean automatic transmission
fluid.
Fill the transmission to the correct level with clean automatic transmission fluid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Locations > Page 5571
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive. The operator of the vehicle controls. the position of the TCS.
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch
in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift
Transmission Control (TC) Switch - Column Shift
Removal and Installation
NOTE: The Transmission Control (TC) switch is not replaceable. If a new TC switch is required,
install a new transmission selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift > Page 5577
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift
Transmission Control (TC) Switch - Floor Shift
Removal and Installation
NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a
new selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5581
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5582
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5583
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5584
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5585
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page
5590
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
5593
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5594
Transmission Speed Sensor: Service and Repair
Speed Sensors
NOTE: Only remove the affected sensor.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Adjustments > Cable and Bracket Adjustment - Column Shift
Shift Interlock Cable: Adjustments Cable and Bracket Adjustment - Column Shift
Cable and Bracket Adjustment - Column Shift
1. Place the gearshift lever in the (D) position.
^ Place a three pound weight on the gearshift lever.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Disconnect the transmission shift cable from the manual control lever.
4. NOTE: Make sure the cable moves freely.
Unlock the lock tab on the transmission shift cable.
5. Place the manual control lever in the (D) position.
1 Place the manual control lever in the first gear position.
2 Move the manual control lever two detents to the (D) position.
6. Connect the transmission shift cable to the manual control lever.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Adjustments > Cable and Bracket Adjustment - Column Shift > Page 5600
7. Lock the transmission shift cable lock tab. 8. Remove the three pound weight. 9. Carefully move
the manual control lever from detent to detent and compare with transmission settings. Verify that
the vehicle will start in PARK
or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated. Carry
out the digital Transmission Range (TR) sensor adjustment. ^
Readjust if necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Adjustments > Cable and Bracket Adjustment - Column Shift > Page 5601
Shift Interlock Cable: Adjustments Cable and Bracket Adjustment - Floor Shift
Cable and Bracket Adjustment - Floor Shift
1. Place the gearshift lever in the (D) position. 2. With the vehicle in NEUTRAL, position the vehicle
on a hoist.
3. Disconnect the transmission shift cable from the manual control lever.
4. NOTE: Make sure the cable moves freely.
Unlock the lock tab on the transmission shift cable.
5. Place the manual control lever in the (D) position.
^ Place the manual control lever in the first gear position.
^ Move the manual control lever three detents to the (D) position.
6. Connect the transmission shift cable to the manual control lever.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Adjustments > Cable and Bracket Adjustment - Column Shift > Page 5602
7. Lock the transmission shift cable lock tab. 8. Carefully move the manual control lever from detent
to detent and compare with transmission settings. Verify that the vehicle will start in PARK
or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated. Carry
out the digital Transmission Range (TR) sensor adjustment. ^
Readjust if necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift
Shift Interlock Cable: Service and Repair Selector Lever Cable and Bracket - Column Shift
Selector Lever Cable and Bracket - Column Shift
Removal and Installation
1. Remove the instrument panel lower finish panel.
2. NOTE: To prevent cable damage, do not apply force to the transmission shift cable assembly
between the steering column transmission selector
lever arm and the steering column bracket.
Disconnect the transmission shift cable from the steering column. ^
Disconnect the transmission shift cable from the transmission selector lever arm and support.
^ Carefully lift the two locking tabs and disconnect the transmission shift cable from the steering
column bracket.
3. Remove the cable retaining screw.
4. Push the rubber grommet and transmission shift cable through the floor panel. 5. With the
vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift > Page
5605
6. NOTE: To prevent shift cable damage, do not apply force to the transmission shift cable between
the manual control lever and the transmission
shift cable bracket.
Disconnect the transmission shift cable from the manual control lever.
7. Carefully pry behind the transmission shift cable lock tab to release the transmission shift cable
from the bracket.
8. Remove the shift cable bracket from the transmission.
^ Remove the bolts.
^ To install, tighten to 25 Nm (18 ft. lbs.).
^ Remove the bracket.
9. Remove the cable from the cable route assist clip located at the transmission bell housing.
10. To install, reverse the removal procedure.
CAUTION: Make sure the cable is inserted into the cable route assist clip. Failure to do so can
result in exhaust contact.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift > Page
5606
^ Adjust the shift cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift > Page
5607
Shift Interlock Cable: Service and Repair Selector Lever Cable and Bracket - Floor Shift
Selector Lever Cable and Bracket - Floor Shift
Removal
1. Lift and remove the floor shift PRNDL trim plate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift > Page
5608
2. Using a small flat-blade screwdriver, lift up on the shift knob bezel and remove the bezel.
3. Remove the two shift lever knob screws and remove the knob.
^ Slide the knob button out when the knob is removed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift > Page
5609
4. Remove the spring from the top of the selector handle. 5. Position the window regulator control
panel aside.
6. Remove the screws and the console finish panel.
7. Disconnect the transmission shift cable from the transmission selector arm.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Cable > Component Information > Service and Repair > Selector Lever Cable and Bracket - Column Shift > Page
5610
8. Remove the left side console access panel.
9. Remove the transmission shift cable retaining clip from the floor shift mechanism through the
console access panel.
10. Push the rubber grommet and transmission shift cable through the floor panel. 11. With the
vehicle in NEUTRAL position it on a hoist.
12. Remove the transmission shift cable from the automatic transmission.
13. Remove the shift cable bracket from the transmission.
^ Remove the bolts and the shift cable bracket.
Installation
1. To install, reverse the removal procedure.
^ Adjust the shift cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift
Shifter A/T: Service and Repair Selector Lever - Column Shift
Selector Lever - Column Shift
Removal
1. WARNING: To avoid accidental deployment and Possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to
the appropriate vehicle shop information to determine the location of the front air bag sensors. The
side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable. Wait at least one minute before proceeding with the
procedure to allow the backup power supply to deplete its energy.
2. Remove the lower steering column opening finish panel.
1 Remove the screw and position the parking brake release handle aside.
2 Remove the screw from the lower steering column opening finish panel.
3 Pull outward to release the retaining clips and remove the lower steering column opening finish
panel.
3. Remove the five screws and the lower steering column opening finish panel reinforcement.
4. Remove the ignition switch lock cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5615
1 Rotate the ignition switch lock cylinder to the RUN position.
2 Press the lock cylinder release pin and remove the ignition switch lock cylinder.
5. Remove the lower steering column shroud.
1 Remove the four screws.
2 Remove the lower steering column shroud.
6. Remove the upper steering column shroud.
7. Disconnect the Transmission Control Switch (TCS) harness connector.
8. Separate the TCS harness from the locators and the gearshift lever cover from the steering
column.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5616
9. CAUTION: Never reinstall the old gearshift lever pin.
Remove the gearshift lever pin and the gearshift lever. Discard the gearshift lever pin.
Installation
1. NOTE: A new gearshift lever pin must be installed whenever removed.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5617
Shifter A/T: Service and Repair Selector Lever - Floor Shift
Selector Lever - Floor Shift
Removal and Installation
1. Lift and remove the floor shift PRNDL trim plate.
2. Using a small flat-blade screwdriver, lift up on the shift knob bezel and remove the bezel.
3. Remove the two shift lever knob screws and remove the knob.
^ Slide the knob button out when the knob is removed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5618
4. Remove the spring from the top of the selector handle. 5. Position the window regulator control
panel aside.
6. Remove the screws and the console finish panel.
7. Remove the left side console access panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5619
8. Disconnect the transmission shift cable from the transmission selector arm.
9. Remove the transmission shift cable retaining clip from the floor shift mechanism through the
console access.
10. Remove the four nuts retaining the floor shift mechanism to the floor.
11. Remove the three bolts retaining the upper shift bracket to the console.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5620
12. Remove the remaining bolt in the upper shift bracket from the console access panel side of the
shift mechanism.
13. Disconnect the floor shift mechanism wire harness connector. 14. Remove the floor shift
mechanism from the console.
15. Disconnect the three electrical connectors from the light bar bezel.
16. Carefully release the retaining clips from the light bar bezel and remove the bezel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever - Column Shift > Page 5621
17. The selector lever is serviced as an assembly. 18. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Selector Lever Indicator Adjustment
1. Remove the upper instrument panel steering column cover. 2. Place the transmission control
selector lever in the (D) position.
^ Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate
two detents counterclockwise ((D) position).
3. Hang a three 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 three 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 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Service and Repair > Torque Converter
Torque Converter: Service and Repair Torque Converter
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
^ A torque converter malfunction has been determined based on complete diagnostic procedures.
^ Converter stud or studs, impeller hub or bushing are damaged.
^ Discoloration (due to overheating).
^ Evidence of transmission assembly or fluid contamination due to the following transmission or
converter failure modes: Major metallic failure.
- Multiple clutches or clutch plate failures.
- Sufficient component wear which results in metallic contamination.
- Internal torque converter contamination present.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Service and Repair > Torque Converter > Page 5630
Torque Converter: Service and Repair Torque Converter Contamination Inspection
Torque Converter Contamination Inspection
Material
CAUTION: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter
or transmission, damage will occur. Use only clean automatic transmission fluid designated for the
transmission and converter being serviced.
1. If a new or remanufactured torque converter is not being installed, the following steps must be
completed. 2. With the torque converter on a bench, pour a small amount of transmission fluid from
the torque converter onto an absorbent white tissue or
through a paper filter and examine the fluid.
3. NOTE: The factory fill fluid is clear, the exchange fluid will be red.
Observe the color and odor of the fluid. The fluid should be clear or red, not brown or black. Odor
may indicate an overheating condition such as clutch disc or band failure.
4. Examine the stain on the tissue for evidence of particles (specks of any kind). Examine the fluid
level indicator for signs of antifreeze (gum or
varnish). If particles are present in the fluid, a new torque converter must be installed.
5. If there are no particles or contamination present, drain the remainder of the transmission fluid
from the torque converter. 6. Add 1.9 liter (2 quarts) of clean automatic transmission fluid into the
converter and agitate by hand. 7. Thoroughly drain the fluid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch,
A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 09-20-14 >
Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift
Torque Converter Clutch: Customer Interest A/T - Uncommanded TCC Lock Up On 1-2 Upshift
TSB 09-20-14
10/19/09
UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION
AND/OR LACK OF POWER DURING SHIFT
FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150
LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT
MERCURY: 2005-2010 Grand Marquis
This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model
line covered.
ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an
un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2
shift. This may result in the perception that the vehicle lacks power or that the transmission is
up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop
(before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual
2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle
should operate normally in park, reverse, neutral and manual 1st gear.
ACTION Follow the Service Procedure for verification and repair.
SERVICE PROCEDURE
1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter
clutch slippage - RPM, while in 2nd, 3rd or 4th gear
with a TCC % reading 0.
a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the
main control valve body for damage. Replace
as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly
of Subassemblies - Main Control Valve Body. (Figure 1)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch,
A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 09-20-14 >
Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 5639
NOTE
THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC
SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR
AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H).
b. If you receive any other reading, this procedure does not apply; follow normal diagnostic
procedures as outlined in the appropriate WSM.
NOTE
IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30
KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092014A 2005-2010 Crown Victoria, 2.3 Hrs.
Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To
Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor
Operations)
092014A 2005-2010 F-150, 2.2 Hrs.
2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair
(Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E195 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch,
A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: >
09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift
Torque Converter Clutch: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On
1-2 Upshift
TSB 09-20-14
10/19/09
UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION
AND/OR LACK OF POWER DURING SHIFT
FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150
LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT
MERCURY: 2005-2010 Grand Marquis
This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model
line covered.
ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an
un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2
shift. This may result in the perception that the vehicle lacks power or that the transmission is
up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop
(before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual
2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle
should operate normally in park, reverse, neutral and manual 1st gear.
ACTION Follow the Service Procedure for verification and repair.
SERVICE PROCEDURE
1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter
clutch slippage - RPM, while in 2nd, 3rd or 4th gear
with a TCC % reading 0.
a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the
main control valve body for damage. Replace
as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly
of Subassemblies - Main Control Valve Body. (Figure 1)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch,
A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: >
09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 5645
NOTE
THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC
SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR
AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H).
b. If you receive any other reading, this procedure does not apply; follow normal diagnostic
procedures as outlined in the appropriate WSM.
NOTE
IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30
KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092014A 2005-2010 Crown Victoria, 2.3 Hrs.
Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To
Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor
Operations)
092014A 2005-2010 F-150, 2.2 Hrs.
2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair
(Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E195 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications > Page 5650
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Page 5651
Transmission Cooler: Description and Operation
Transmission Cooling
The transmission fluid cooling system, without an auxiliary transmission fluid cooler, consists of: ^
an in-tank fluid cooler inlet tube.
^ a non-repairable in-tank transmission fluid cooler.
^ an in-tank fluid cooler return tube.
The transmission fluid cooling system, with an auxiliary transmission fluid cooler, consists of: ^
an in-tank fluid cooler inlet tube.
^ a non-repairable in-tank transmission fluid cooler.
^ an auxiliary fluid cooler inlet tube.
^ an auxiliary transmission fluid cooler.
^ an auxiliary fluid cooler return tube.
The transmission fluid flows from the transmission to the in-tank transmission fluid cooler, to the
auxiliary transmission fluid cooler and returns to the transmission.
For fluid cooler flow testing and backflushing and cleaning procedures, refer to Transmission Fluid
Cooler Backflushing and Cleaning.
4R70E, 4R75E Transmissions With Auxiliary Transmission Fluid Cooler
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Page 5652
4R70E, 4R75E Transmissions Without Auxiliary Transmission Fluid Cooler
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Page 5653
626 Transmission With Auxiliary Transmission Fluid Cooler
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E
Transmission Cooler: Testing and Inspection Automatic Transmission - 4R70E/4R75E
Initial Inspection
Transmission Cooling
Inspection and Verification
CAUTION: When internal wear/damage occurs in the transmission, metal particles, clutch plate
material and band material can travel into the torque converter, the fluid cooler tubes, the in-tank
transmission fluid cooler and the auxiliary transmission fluid cooler, if so equipped. These
contaminants are a major cause of recurring transmission concerns. To prevent future concerns,
remove these contaminants from the cooling system before placing the transmission back into use.
Refer to fluid cooler flow testing, backflushing and cleaning, torque converter cleaning and
inspection and flushing.
1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and
system leaks. Repair as necessary.
^ Install a new or remanufactured radiator when fluid is found leaking from the intake transmission
fluid cooler.
^ Install a new auxiliary transmission fluid cooler if there is leakage from the fluid cooler.
2. If the fault is not visually evident, GO to Symptom Chart. See: Diagnosis By Symptom
Component Test
Transmission Fluid Cooler Leaks at Radiator
Transmission fluid may leak between the radiator transmission fluid cooler and the transmission
fluid cooler fitting (not the cooler line into the fitting), which may result in a residue of transmission
fluid on the radiator tank around the fluid cooler fitting. Insufficient thread sealer on the
transmission fluid cooler fitting may cause this.
1. Clean the area around the transmission fluid cooler fittings.
2. Verify that transmission fluid is leaking between the transmission fluid cooler and the
transmission fluid cooler fitting (not the transmission fluid
cooler line fitting into the transmission fluid cooler fitting).
3. Remove the radiator from the vehicle and place it on a flat surface with the transmission fluid
cooler fittings facing upward.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E > Page 5656
4. 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.
Clean the area around the transmission fluid cooler fittings so that contaminants do not enter the
transmission fluid cooler when the transmission fluid cooler fittings are removed.
5. NOTE: Remove only one transmission fluid cooler fitting at a time, otherwise the cooler may
drop into the radiator.
Remove the upper transmission fluid cooler fitting.
6. Once the fitting is removed from the transmission fluid cooler, verify that there is a gasket
between the transmission fluid cooler and the inside of
the radiator tank. ^
If there is no gasket, install a new radiator.
^ If there is a gasket, proceed to the next step.
7. Inspect the transmission fluid cooler fitting threads for damage.
^ If the threads are damaged, install a new radiator.
^ If the threads show no sign of damage, proceed to the next step.
8. CAUTION: Thread sealant or tape should never be used on the threads of the transmission fluid
cooler fittings. The use of such materials will
create a leak path.
Install a new O-ring on the transmission fluid cooler fitting.
9. NOTE: Do not use air tools to tighten the transmission fluid cooler fitting. Use a hand-operated
torque wrench only.
Making sure that the gasket between the transmission fluid cooler and the inside of the radiator
tank is still in place, install the transmission fluid cooler fitting.
10. Follow the procedure to install a new O-ring on the other transmission fluid cooler fitting. 11.
Make sure that no radiator coolant has entered the transmission fluid cooler. Install the radiator in
the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E > Page 5657
12. Verify that both the transmission and the engine cooling system are at the correct fluid levels.
Transmission Fluid Cooler
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission
fluid cooler tubes and the in-tank cooler if equipped must be cleaned and backflushed. Use a
suitable torque converter/fluid cooler cleaner.
NOTE: If the vehicle is equipped with a Oil-To-Air (OTA) cooler, a new OTA must be installed.
NOTE: Cleaning and backflushing the transmission fluid cooling system along with following all the
normal cleaning and inspection procedures during disassembly and reassembly will keep
contamination from reentering the transmission and causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and transmission fluid
cooler. These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back into use.
Auxiliary Transmission Fluid Cooler
Transmission Fluid Cooler Flow Test
NOTE: The transmission linkage/cable adjustment, fluid level and line pressure must be within
specification before carrying out this test.
1. Remove fluid level indicator from fluid filler tube. 2. Place funnel in fluid filler tube. 3. Position the
vehicle on a hoist. 4. Remove the cooler return line (top fitting) from the fitting on the transmission
case. 5. Connect one end of a hose to the cooler return line and route other end of the hose up to a
point where it can be inserted into the funnel at the fluid
filler tube.
6. Remove the safety stands and lower the vehicle. Insert end of hose into the funnel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E > Page 5658
7. Start the engine and run it at idle with the transmission in NEUTRAL. 8. When fluid flows from
the hose in a steady stream, a liberal amount of fluid should be observed. Liberal is about 1 liter (1
quart) delivered in 15
seconds. If a liberal flow is observed, the test is complete.
9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return line and
connect it to the converter outlet fitting (bottom
fitting) on the transmission case.
10. Repeat steps 6 and 7. If flow is now approximately 1 liter (1 quart) in 15 seconds, refer to
Transmission Fluid Cooler - Backflushing and
Cleaning. If the flow is still not approximately 1 liter (1 quart) in 15 seconds, repair or install pump
and or converter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E > Page 5659
Transmission Cooler: Testing and Inspection Automatic Transmission - 6HP26
Initial Inspection
Transmission Cooling
Inspection and Verification
CAUTION: When internal wear or damage occurs in the transmission, metal particles, clutch plate
material and band material can travel into the torque converter, the fluid cooler tubes, the in-tank
transmission fluid cooler and the auxiliary transmission fluid cooler, if so equipped. These
contaminants are a major cause of recurring transmission concerns. To prevent future concerns,
remove these contaminants from the cooling system before placing the transmission back into use.
1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and
system leaks. Repair as necessary.
^ Install a new or remanufactured radiator when fluid is found leaking from the in-tank transmission
fluid cooler.
^ Install a new O-ring when transmission fluid is found leaking between the radiator transmission oil
cooler and the transmission oil cooler fitting (not the cooler line into the fitting).
^ Install a new auxiliary transmission fluid cooler if there is leakage from the fluid cooler.
2. If the fault is not visually evident, GO to Symptom Chart. See: Diagnosis By Symptom
Component Test
Transmission Fluid Cooler Leaks at Radiator
Transmission fluid may leak between the radiator transmission fluid cooler and the transmission
fluid cooler fitting (not the cooler line into the fitting), which may result in a residue of transmission
fluid on the radiator tank around the fluid cooler fitting. Insufficient thread sealer on the
transmission fluid cooler fitting may cause this.
1. Clean the area around the transmission fluid cooler fittings.
2. Verify that transmission fluid is leaking between the transmission fluid cooler and the
transmission fluid cooler fitting (not the transmission fluid
cooler line fitting into the transmission fluid cooler fitting).
3. Remove the radiator from the vehicle and place it on a flat surface with the transmission fluid
cooler fittings facing upward.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E > Page 5660
4. 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.
Clean the area around the transmission fluid cooler fittings so that contaminants do not enter the
transmission fluid cooler when the transmission fluid cooler fittings are removed.
5. NOTE: Remove only one transmission fluid cooler fitting at a time, otherwise the cooler may
drop into the radiator.
Remove the upper transmission fluid cooler fitting.
6. Once the fitting is removed from the transmission fluid cooler, verify that there is a gasket
between the transmission fluid cooler and the inside of
the radiator tank. ^
If there is no gasket, install a new radiator.
^ If there is a gasket, proceed to the next step.
7. Inspect the transmission fluid cooler fitting threads for damage.
^ If the threads are damaged, install a new radiator.
^ If the threads show no sign of damage, proceed to the next step.
8. CAUTION: Thread sealant or tape should never be used on the threads of the transmission fluid
cooler fittings. The use of such materials will
create a leak path.
Install a new O-ring on the transmission fluid cooler fitting.
9. NOTE: Do not use air tools to tighten the transmission fluid cooler fitting. Use a hand-operated
torque wrench only.
Making sure that the gasket between the transmission fluid cooler and the inside of the radiator
tank is still in place, install the transmission fluid cooler fitting.
10. Follow the procedure to install a new O-ring on the other transmission fluid cooler fitting. 11.
Make sure that no radiator coolant has entered the transmission fluid cooler. Install the radiator in
the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Automatic Transmission - 4R70E/4R75E > Page 5661
12. Verify that both the transmission and the engine cooling system are at the correct fluid levels.
Transmission Fluid Cooler
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission
fluid cooler and transmission fluid cooler tubes must be cleaned and backflushed. Use a torque
converter/oil cooler cleaner.
NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the
normal cleaning and inspection procedures during disassembly and reassembly, will keep
contaminants from entering the transmission, causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and transmission fluid
cooler. These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back into use.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26
Transmission Cooler: Service and Repair Automatic Transmission - 6HP26
Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler - Backflushing and Cleaning
Material
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the cooler lines and install a new cooler before placing the transmission in use.
1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is
indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines.
3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting
them to the cleaner.
Connect the cleaner pressure and return lines appropriately. 1
Connect the pressure line to the fluid cooler inlet tube.
2 Connect the return line to the fluid cooler outlet tube.
3 Place the outlet end of the return line in the fluid tank reservoir.
4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system.
Switch the fluid pumps on. Allow the fluid to circulate a minimum of five minutes.
5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7.
Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove
the rubber hoses from the fluid cooler tubes.
Transmission Fluid Fill Procedure
6HP26 Transmission Fluid Fill Procedure
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
NOTE: If the vehicle has been operated for an extended period, at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the fluid needs to cool down to obtain an
accurate reading.
NOTE: The transmission fluid temperature must not be allowed to exceed 50°C (122°F) when
checking the fluid level. The fluid temperature should be between 30°C - 50°C (86°F - 122°F) when
checking the fluid level.
This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the
transmission operation and could result in transmission failure. Under normal circumstances, the
fluid level should be checked during normal maintenance. If the transmission starts to slip, shifts
slowly or shows signs of fluid leaking, the fluid level should be checked.
1. With the transmission in P (PARK), the engine at idle and foot pressed on the brake, move the
range selector lever through each gear and allow
engagement of each gear. Place the transmission range selector lever in the P position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5664
2. With the vehicle idling (600 - 750 rpm) in PARK, position it on a hoist.
3. Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical
connector.
4. CAUTION: The use of any other transmission fluid can result in the transmission failing to
operate in a normal manner or transmission failure.
Fill the transmission. ^
Add clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the
fluid runs out of the bottom of the hole.
5. Install the fluid fill plug.
6. Move the transmission range selector lever through all the gear ranges, checking for
engagements. 7. If more fluid is needed, start the engine. Remove the fluid fill plug on the side of
the case, fill with clean automatic transmission fluid until fluid
just starts to dribble out of the hole and reinstall the fill plug.
Transmission Fluid Cooler Leaks at Radiator
Auxiliary Transmission Fluid Cooler - 6HP26
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5665
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
3. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5666
4. Remove the push pin retainers and remove the air deflector.
5. Remove the three bolts and remove the auxiliary transmission fluid cooler.
Installation
1. Install the auxiliary transmission fluid cooler and install the three bolts.
2. Position the air deflector and install the push pin retainers.
3. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler. 4. With the vehicle
idling (600 - 750 rpm) in PARK, and the transmission temperature at 30°C - 50°C (86°F - 122°F),
check and adjust the
transmission fluid level.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5667
5. Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical
connector.
6. CAUTION: The use of any other transmission fluid can result in the transmission failing to
operate in a normal manner or transmission failure.
Fill the transmission. ^
Add clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the
fluid runs out of the bottom of the hole.
7. Install the fluid fill plug. 8. Move the transmission range selector lever through all the gear
ranges, checking for engagements.
9. If more fluid is needed, start the engine. Remove the fluid fill plug on the side of the case, fill with
clean automatic transmission fluid until fluid
just starts to dribble out of the hole. Install the fill plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5668
Transmission Cooler: Service and Repair Automatic Transmission - 4R70E/4R75E
Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
Material
1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The
use of these products could cause internal
transmission components to fail; this will effect the operation of the transmission.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to
make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush
equipment if flow is weak or contaminated.
2. If equipped, remove and discard the transmission fluid in-line filter. 3. To aid in attaching the
cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the
transmission end of the steel
transmission cooler lines as described below. ^
Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line).
^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the
outlet end of this hose in the tank reservoir.
4. Turn on the pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and
off will help dislodge contaminants in cooler
system).
5. Switch off the pump and disconnect the pressure hose from the transmission cooler return line.
6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler
return line) until all fluid is removed. 7. Remove the rubber return hose from the remaining steel
cooler line.
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Special Tool(s)
Material
Draining, all vehicles using a suitable flush and fill machine
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5669
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for normal
or severe duty fluid maintenance.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to
change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid
cooler tube after the fluid cooler on the cooler return line. This will
help remove any foreign material trapped in the fluid coolers.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the
engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F),
check and adjust the transmission fluid
level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until
the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Draining, all vehicles not using a suitable flush and fill machine
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan. 4. Do not remove the fluid filter. It
is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Clean and inspect the transmission fluid pan, transmission fluid gasket and magnet. 6.
Thoroughly flush the cooler tubes.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5670
Refill
1. Position the magnet into the transmission fluid pan.
2. NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket. 1
Position the fluid pan with the gasket in place.
2 Install the bolts.
3. CAUTION: The use of any other transmission fluid can result in the transmission failing to
operate in a normal manner or transmission failure.
Fill the transmission. ^
Add 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the fluid filler
tube.
4. Start the engine. Move the transmission range selector lever through all the gear ranges,
checking for engagements. 5. With the engine running and the transmission at normal operating
temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid
level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until
the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Transmission Fluid Cooler Leaks at Radiator
Auxiliary Transmission Fluid Cooler 4R70E, 4R75E
Special Tool(s)
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5671
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
3. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid
cooler.
4. Remove the push pin retainers and remove the air deflector.
5. Remove the three bolts and remove the auxiliary transmission fluid cooler.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Automatic Transmission - 6HP26 > Page 5672
1. Install the auxiliary transmission fluid cooler and install the three bolts.
2. Position the air deflector and install the push pin retainers.
3. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler. 4. Fill the transmission
with the specified type and quantity of transmission fluid. 5. Check for leaks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive. The operator of the vehicle controls. the position of the TCS.
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch
in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift
Transmission Control (TC) Switch - Column Shift
Removal and Installation
NOTE: The Transmission Control (TC) switch is not replaceable. If a new TC switch is required,
install a new transmission selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5678
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift
Transmission Control (TC) Switch - Floor Shift
Removal and Installation
NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a
new selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 06-5-1 > Mar > 06 >
Engine Controls - Cold Start Rough Idle Condition
Transmission Mount: Customer Interest Engine Controls - Cold Start Rough Idle Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 06-5-1 > Mar > 06 >
Engine Controls - Cold Start Rough Idle Condition > Page 5687
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 06-5-1 >
Mar > 06 > Engine Controls - Cold Start Rough Idle Condition
Transmission Mount: All Technical Service Bulletins Engine Controls - Cold Start Rough Idle
Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 06-5-1 >
Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 5693
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Page 5694
Transmission Mount: Service and Repair
Transmission Insulator and Retainer
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the rear transmission support nuts. 3. Install a suitable transmission jack.
4. Slightly raise the rear of the transmission and remove the bolts. Remove the rear transmission
mount.
Installation
1. Install the rear transmission mount and the bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Technical Service Bulletins > Page 5695
2. Lower the transmission onto the crossmember and install the nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5699
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5700
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5701
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5702
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5703
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test
Port, A/T > Component Information > Locations
Transmission Pressure Test Port: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5711
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 5714
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 5715
Transmission Speed Sensor: Service and Repair
Speed Sensors
NOTE: Only remove the affected sensor.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 09-20-14 > Oct > 09 > A/T Uncommanded TCC Lock Up On 1-2 Upshift
Valve Body: Customer Interest A/T - Uncommanded TCC Lock Up On 1-2 Upshift
TSB 09-20-14
10/19/09
UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION
AND/OR LACK OF POWER DURING SHIFT
FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150
LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT
MERCURY: 2005-2010 Grand Marquis
This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model
line covered.
ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an
un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2
shift. This may result in the perception that the vehicle lacks power or that the transmission is
up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop
(before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual
2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle
should operate normally in park, reverse, neutral and manual 1st gear.
ACTION Follow the Service Procedure for verification and repair.
SERVICE PROCEDURE
1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter
clutch slippage - RPM, while in 2nd, 3rd or 4th gear
with a TCC % reading 0.
a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the
main control valve body for damage. Replace
as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly
of Subassemblies - Main Control Valve Body. (Figure 1)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 09-20-14 > Oct > 09 > A/T Uncommanded TCC Lock Up On 1-2 Upshift > Page 5724
NOTE
THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC
SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR
AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H).
b. If you receive any other reading, this procedure does not apply; follow normal diagnostic
procedures as outlined in the appropriate WSM.
NOTE
IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30
KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092014A 2005-2010 Crown Victoria, 2.3 Hrs.
Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To
Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor
Operations)
092014A 2005-2010 F-150, 2.2 Hrs.
2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair
(Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E195 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-20-14 > Oct >
09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift
Valve Body: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On 1-2 Upshift
TSB 09-20-14
10/19/09
UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION
AND/OR LACK OF POWER DURING SHIFT
FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150
LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT
MERCURY: 2005-2010 Grand Marquis
This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model
line covered.
ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an
un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2
shift. This may result in the perception that the vehicle lacks power or that the transmission is
up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop
(before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual
2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle
should operate normally in park, reverse, neutral and manual 1st gear.
ACTION Follow the Service Procedure for verification and repair.
SERVICE PROCEDURE
1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter
clutch slippage - RPM, while in 2nd, 3rd or 4th gear
with a TCC % reading 0.
a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the
main control valve body for damage. Replace
as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly
of Subassemblies - Main Control Valve Body. (Figure 1)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-20-14 > Oct >
09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 5730
NOTE
THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC
SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR
AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H).
b. If you receive any other reading, this procedure does not apply; follow normal diagnostic
procedures as outlined in the appropriate WSM.
NOTE
IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30
KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092014A 2005-2010 Crown Victoria, 2.3 Hrs.
Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To
Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor
Operations)
092014A 2005-2010 F-150, 2.2 Hrs.
2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair
(Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E195 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5731
Valve Body: Specifications
Main control valve body bolts ..............................................................................................................
.................................................. 10 Nm (89 inch lbs.) Main control valve body cover plate bolts
............................................................................................................................................. 10 Nm
(89 inch lbs.) Main control valve body separator plate bolts
....................................................................................................................................... 10 Nm (89
inch lbs.) Main control valve body reinforcement plates
....................................................................................................................................... 10 Nm (89
inch lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E
Valve Body: Service and Repair 4R70E/4R75E
Main Control Valve Body
Special Tool(s)
Removal
1. Drain transmission fluid and remove the transmission fluid pan and filter.
2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector
ends. Carefully pry up on the locking tabs to
disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
Disconnect the molded lead frame from the solenoids. 1
Disconnect the shift solenoid SSA and SSB.
2 Disconnect the Torque Converter Clutch (TCC).
3 Disconnect the Electronic Pressure Control (EPC) solenoid.
4 Disconnect the bulkhead inter-connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5734
3. Remove the manual control valve detent lever spring.
1 Remove the bolt.
2 Remove the manual control valve detent lever spring.
4. Remove the 25 valve body-to-case bolts and the EPC bracket bolt.
5. Remove the main control valve body and discard the pump outlet screen.
Installation
1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the
manual valve in the correct location prior to installing
the bolts.
Position the main control valve body gasket and main control valve body using the 2 alignment
bolts as a guide.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5735
2. NOTE: The main control valve body bolts will be tightened in later steps.
Loosely install the 10 long main control valve body bolts.
3. NOTE: Lubricate the Electronic Pressure Control (EPC) solenoid O-rings with clean automatic
transmission fluid.
Install the EPC solenoid. 1
Install the EPC solenoid.
2 Install the EPC solenoid bracket and bolt.
4. NOTE: The main control valve body bolts will be tightened in later steps.
Loosely install the 12 short main control valve body bolts.
5. Install the manual control valve detent lever spring.
1 Position the manual control valve detent lever spring.
2 Install the bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5736
6. Tighten the main control valve body bolts in the sequence shown.
7. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and
not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a
good contact, install a new lead frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5737
8. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the
connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in
place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make
sure that the terminals pass fully through the connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the
connector in place. Make sure that the terminals pass fully through the connector slots.
9. Install the transmission filter and pan.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5738
Valve Body: Service and Repair 6HP26
Main Control Valve Body
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on
the connector.
3. Remove the transmission fluid pan drain plug and allow the fluid to drain.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5739
4. Install the fluid pan drain plug.
^ Tighten to 8 Nm (71 inch lbs.).
5. NOTE: The transmission fluid pan, gasket, filter and magnets are serviced as a complete unit.
Remove the transmission fluid pan assembly.
6. Press the release tab and pull down on the bulkhead connector retainer.
7. With the release tab down, pull the outer shell of the bulkhead electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5740
8. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will
cause damage to the mechatronic unit.
Pull the outer shell of the bulkhead electrical connector out of the transmission.
9. Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly.
Installation
1. Position the mechatronic assembly in place and loosely install the 10 retaining bolts.
2. Tighten the mechatronic bolts in the sequence shown.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5741
3. Install new O-rings seals on the outer shell of the bulkhead electrical connector.
4. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will
cause damage to the mechatronic unit.
With the release tab down, push the outer shell of the bulkhead electrical connector into the
transmission.
5. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place.
6. Install the fluid pan.
^ Tighten the bolts in a crisscross pattern.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5742
7. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
8. Remove the fluid fill plug.
^ The fill plug is located on the RH rear side of the case near the transmission electrical connector.
9. CAUTION: The use of any other transmission fluid than specified can result in the transmission
failing to operate correctly or transmission
failure.
Fill the transmission. ^
Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid
fill hole. Stop when the fluid runs out of the bottom of the hole.
10. Install the fluid fill plug. 11. Start the engine. Move the transmission range selector lever
through all the gear ranges, checking for engagements. 12. With the engine idling (600 - 750 rpm)
in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 4R70E/4R75E > Page 5743
transmission fluid level.
13. With the engine still running in PARK, check the fluid level. If more fluid is needed, remove the
fluid fill plug and fill with clean automatic
transmission fluid until the fluid runs out of the bottom of the hole.
14. Install the fluid fill clue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair
Differential Case: Service and Repair
Differential Case Runout Check
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Page 5748
Special Tool(s)
1. Remove the front drive axle assembly. 2. Remove the axle shafts from the differential assembly.
3. CAUTION: Do not damage the aluminum differential housing while carrying out these
procedures.
Using the special tools, mount the differential housing to a work bench. 1
Attach the special tools to the differential housing with four bolts that retain the differential housing
cover to the differential housing.
2 Attach the special tools together with two 3/8 inch x 1-1/2 inch bolts.
4. Install the special tools, measure and record the differential ring gear backlash between teeth in
four opposing places.
^ If the backlash between teeth exceeds the specification of 0.254 - 0.305 mm (0.010 - 0.012 inch),
the cause may be a warped ring gear, differential bearings, or a damaged differential case. To
determine the cause of the excessive backlash, remove the dial indicator and proceed as follows:
5. Install the special tool by placing the spreader pins in the hole in the Differential Housing (Plate)
Spreader.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Page 5749
6. Assemble the special tool.
1 Install the special tool.
2 Attach the special tool and position the tip in the Differential Housing (Plate) Spreader hole.
7. CAUTION: Overspreading can damage the differential housing.
NOTE: Tighten and loosen the Differential Carrier Spreader screw several times to normalize the
Differential Housing (Plate) Spreader Adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to specifications. 1
Adjust the Dial Indicator with Holding Fixture to zero.
2 Tighten the screw until the differential housing is spread to specification.
3 Remove the Dial Indicator with Holding Fixture and the Clutch Housing Gauge.
8. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not
be visible.
Remove the bearing caps. 1
Remove the bolts.
2 Remove the bearing caps.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Page 5750
9. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly. 1
Position the wood blocks at the top and bottom of the differential case.
2 Pry the differential assembly with the bearing cups and shims out of the differential housing.
3 Remove the special tool.
10. Separate the bearing shims and cones from the differential assembly and tag them left and
right for assembly.
11. Remove the ring gear.
^ Remove the ten bolts.
^ Use a drift punch to separate the ring gear from the differential case.
12. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating
bearing overheating or failure.
NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
Install the differential case with the bearing cups and all the shims in the housing. 1
Position the differential case with the bearing cups and shims in their original location.
2 Install the bearing caps.
3 Install the bolts.
4 Rotate the differential case to make sure the bearings have seated correctly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Page 5751
13. Install the special tool.
14. Rotate the differential case and check the differential case runout.
^ If the runout does not exceed the specification, install a new ring gear and pinion.
^ If runout exceeds the specification, the ring gear is true and the condition is due to differential
case/differential bearing damage.
^ Inspect the differential bearings and the differential case. Always install new differential bearings
when installing a new differential case, or if a bearing condition is questionable.
15. Remove the bearing caps, and the differential case with the bearing cups and shims from the
housing.
16. If necessary, using the special tools, remove the differential bearings.
17. CAUTION: Press against the differential bearing inner cone only.
Install the new differential bearings. 1
Position the appropriate differential bearing (RH or LH).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Page 5752
2 Using a suitable press and the special tool, install the differential bearing.
^ Repeat the steps for the other differential bearing.
18. NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
NOTE: Recheck the flange runout.
Install the differential case with the bearing cups and the shims in the housing. 1
Position the differential case with the bearing cups and shims in their original location.
2 Install the bearing caps.
3 Install the bolts.
4 Rotate the differential case to make sure the bearings have seated correctly.
19. Install the special tool.
20. NOTE: If the runout is still excessive, install a new differential case.
Check the runout with the new differential bearings. If the runout does not exceed the specification,
use the new differential bearings for assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Page 5753
21. Remove the bolts.
22. Remove the differential case with the bearing cups and the shims from the housing.
1 Remove the bearing caps.
2 Remove the differential case with the bearing cups and the shims from the housing.
23. Install the ring gear and the differential assembly. 24. Install the axle shafts in the differential
assembly. 25. Install the front drive axle assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Front Differential Fluid Capacity Ford 8.8 Inch Ring ............................................................................
....................................................................................................... 3.6 pints (1.7 liters) 0.38 in
(9.56mm) below bottom if differential housing fill hole.
Rear Differential Fluid Capacity Ford 9.75 Inch Ribbed Cover Conventional.......................................
..............................................................................................................................................................
...... 4.25 pints (0.9 in [23mm] below fill hole)
Traction-Loc .........................................................................................................................................
.................................. 4.25 + 4oz Friction Modifier * (0.9 in [23mm] below fill hole)
Smooth Cover Conventional.................................................................................................................
.......................................................................................... 4.25 pints (0.9 in [23mm] below fill hole)
Traction-Loc .........................................................................................................................................
.................................. 4.25 + 4oz Friction Modifier * (0.9 in [23mm] below fill hole)
*Install Friction Modifier in axle before installing lubricant.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 5758
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Front Differential Motorcraft SAE 80W-90 Premium Rear Axle Lubricant
............................................................................................................................... XY-80W90-QL
Rear Differential Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant
............................................................................................................ XY-75W140-QL Additive
Friction Modifier ...................................................................................................................................
.......................................................... XL-3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair
Differential Output Shaft Bearing: Service and Repair
Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Page 5763
Material
1. Remove the halfshaft assembly.
2. Using the special tools, remove the stub shaft pilot bearing seal.
3. Using the special tools, remove the stub shaft pilot bearing.
1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing.
2 Remove the bearing.
4. Inspect the seal journal for rust, nicks and scratches. Polish the seal journal surface with fine
crocus cloth, if necessary. 5. Lubricate the new stub shaft pilot bearing with axle lubricant.
6. CAUTION: Installation of the stub shaft pilot bearing or stub shaft oil seal without the correct
tools can result in early bearing or seal failure. If
the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a
new one.
Place the stub shaft pilot bearing onto the special tools.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Page 5764
7. Install the stub shaft pilot bearing into the rear axle housing bore.
8. Install the seal onto the special tools.
9. Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft
pilot bearing seal.
^ Strike only the handle. Directly striking the installer tool will damage the seal.
10. CAUTION: Use the seal protector to avoid damaging the seal with the halfshaft.
CAUTION: Inspect the stub shaft seal journal for rust, nicks, or scratches prior to installing the
halfshaft. Polish the seal journal with fine crocus cloth, if required.
Install the halfshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair
Pinion Flange: Service and Repair
Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
Material
Removal
CAUTION: Remove the rear wheel and tire assemblies, brake calipers, and brake discs to prevent
brake drag during the drive pinion bearing preload adjustment.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations. Failure to follow these instructions may
result in personal injury and vehicle damage.
Position the vehicle on a hoist.
2. Remove the rear wheel and tire assemblies.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 5768
3. CAUTION: Do not allow the brake caliper to hang from the brake hose. Provide a suitable
support.
Remove the rear brake calipers, and the brake discs. Position the brake calipers aside.
4. Remove the rear driveshaft assembly.
5. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain
rotation of the drive pinion gear through several
revolutions.
6. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.
Use the special tool to hold the pinion flange while removing the pinion nut.
7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance
during installation.
8. Using the special tool, remove the drive pinion flange.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 5769
9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a
hammer until the pinion seal is removed.
Installation
1. Lubricate the lips of the new drive pinion seal with grease.
2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a
new seal.
Using the special tool, install the drive pinion seal.
3. Lubricate the drive pinion flange splines with rear axle lubricant.
4. NOTE: Disregard the index marks if installing a new drive pinion flange.
Position the drive pinion flange.
5. Using the special tool, install the drive pinion flange.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Page 5770
6. Position the new drive pinion nut.
7. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to
reduce preload, install a new drive pinion
collapsible spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the nut. ^
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (inch pound)
torque wrench.
^ If the preload recorded prior to disassembly is lower than the specification for used bearings,
tighten the nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, tighten the nut to the original reading as recorded.
^ Refer to the torque specification for used pinion bearings in the Specifications portion.
8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the
threads of the original bolts.
CAUTION: Align the index marks.
CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the
yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
Install the rear driveshaft.
9. Install the rear brake discs, and the brake calipers.
10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. 12. If equipped with air
suspension, reactivate the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential
Seals and Gaskets: Service and Repair Rear Differential
Drive Pinion Flange and Drive Pinion Seal
Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
Material
Removal
CAUTION: Remove the rear wheel and tire assemblies, brake calipers, and brake discs to prevent
brake drag during the drive pinion bearing preload adjustment.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations. Failure to follow these instructions may
result in personal injury and vehicle damage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5775
Position the vehicle on a hoist.
2. Remove the rear wheel and tire assemblies.
3. CAUTION: Do not allow the brake caliper to hang from the brake hose. Provide a suitable
support.
Remove the rear brake calipers, and the brake discs. Position the brake calipers aside.
4. Remove the rear driveshaft assembly.
5. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain
rotation of the drive pinion gear through several
revolutions.
6. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.
Use the special tool to hold the pinion flange while removing the pinion nut.
7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance
during installation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5776
8. Using the special tool, remove the drive pinion flange.
9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a
hammer until the pinion seal is removed.
Installation
1. Lubricate the lips of the new drive pinion seal with grease.
2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a
new seal.
Using the special tool, install the drive pinion seal.
3. Lubricate the drive pinion flange splines with rear axle lubricant.
4. NOTE: Disregard the index marks if installing a new drive pinion flange.
Position the drive pinion flange.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5777
5. Using the special tool, install the drive pinion flange.
6. Position the new drive pinion nut.
7. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to
reduce preload, install a new drive pinion
collapsible spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the nut. ^
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (inch pound)
torque wrench.
^ If the preload recorded prior to disassembly is lower than the specification for used bearings,
tighten the nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, tighten the nut to the original reading as recorded.
^ Refer to the torque specification for used pinion bearings in the Specifications portion.
8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the
threads of the original bolts.
CAUTION: Align the index marks.
CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the
yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
Install the rear driveshaft.
9. Install the rear brake discs, and the brake calipers.
10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. 12. If equipped with air
suspension, reactivate the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5778
Stub Shaft Pilot Bearing and Seal
Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5779
Material
1. Remove the halfshaft assembly.
2. Using the special tools, remove the stub shaft pilot bearing seal.
3. Using the special tools, remove the stub shaft pilot bearing.
1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing.
2 Remove the bearing.
4. Inspect the seal journal for rust, nicks and scratches. Polish the seal journal surface with fine
crocus cloth, if necessary. 5. Lubricate the new stub shaft pilot bearing with axle lubricant.
6. CAUTION: Installation of the stub shaft pilot bearing or stub shaft oil seal without the correct
tools can result in early bearing or seal failure. If
the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a
new one.
Place the stub shaft pilot bearing onto the special tools.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5780
7. Install the stub shaft pilot bearing into the rear axle housing bore.
8. Install the seal onto the special tools.
9. Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft
pilot bearing seal.
^ Strike only the handle. Directly striking the installer tool will damage the seal.
10. CAUTION: Use the seal protector to avoid damaging the seal with the halfshaft.
CAUTION: Inspect the stub shaft seal journal for rust, nicks, or scratches prior to installing the
halfshaft. Polish the seal journal with fine crocus cloth, if required.
Install the halfshaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Differential > Page 5781
Seals and Gaskets: Service and Repair Front Differential
Drive Pinion Seal
Special Tool(s)
Removal
1. Remove the front axle universal joint flange.
2. CAUTION: Do not damage the front axle housing.
Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with
a hammer to remove the pinion seal.
Installation
1. Clean the pinion seal bore, and use the Drive Pinion Oil Seal Installer to install the pinion seal. 2.
Install the front axle universal joint flange.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Front Drive Halfshaft
Axle Shaft Assembly: Specifications Front Drive Halfshaft
General Specifications
General Specifications
Torque Specifications
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Front Drive Halfshaft > Page 5787
Axle Shaft Assembly: Specifications Rear Drive Halfshaft
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Page 5788
Axle Shaft Assembly: Description and Operation
Front Drive Halfshafts
Part 1 Of 2
Part 2 Of 2
Front Wheel Halfshaft and Joint, Disassembled View
New halfshaft components are available as follows: ^
A repair kit includes the boots, clamps, snap ring, retaining ring, and grease.
^ A new inboard CV joint (plunge type).
^ A new outboard CV joint and interconnecting shaft assembly includes the outboard front wheel
halfshaft joint (fixed type), boot, and clamps.
^ A new integrated wheel end disconnect assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft
Axle Shaft Assembly: Service and Repair Front Drive Halfshaft
Removal and Installation
Halfshaft
Removal and Installation
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the left rear
quarter trim panel. Failure to do so can result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these operations.
Position the vehicle on a hoist.
2. Remove the front wheel and tire assembly.
3. Remove the dust cap.
4. Remove the axle nut.
^ Discard the axle nut.
5. Remove the vacuum/vent line at the vacuum/vent port of the integrated wheel end disconnect.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5791
6. Remove the three bolts retaining the integrated wheel end disconnect to the steering knuckle.
7. Remove the tie rod end nut.
^ Disconnect the tie rod end from the steering knuckle.
^ Discard the tie rod end nut.
8. Remove the upper ball joint nut.
^ Disconnect the upper ball joint from the steering knuckle.
^ Discard the upper ball joint nut.
9. CAUTION: Do not damage the hub seal.
NOTE: Allow the steering knuckle to swing outboard while keeping the constant velocity shaft
pushed inboard.
Once clearance is available, remove the constant velocity shaft joint outboard end and integrated
wheel end disconnect from the steering knuckle hub bearing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5792
10. Remove the integrated wheel end disconnect from the outboard constant velocity joint housing.
11. Remove the six bolts retaining the halfshaft to the axle.
12. Separate the halfshaft from the axle and the hub, and remove the assembly from the vehicle.
13. CAUTION: Verify the spline engagement by checking for spline lash before installing the
halfshaft nut.
To install, reverse the removal procedure. ^
Install a new axle nut, tie rod end nut and an upper ball joint nut.
Disassembly and Assembly
Halfshaft
Special Tool(s)
Disassembly
1. Remove the halfshaft from the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5793
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.
5. Remove the inboard CV joint housing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5794
6. Index-mark the inner race and ball cage.
7. Remove the six balls.
8. Remove the snap ring.
9. Remove the inner race and the ball cage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5795
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
1. Position the outboard boot on the shaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5796
2. Pack the outboard CV joint with 165 grams (5.82 ounces) of grease.
1 Use constant velocity joint grease or equivalent provided in the boot kit.
2 Spread any remaining grease from the kit evenly inside the boot.
3. Install the outboard boot.
1 Clean the boot mounting surface.
2 Seat the boot in the joint boot groove.
4. Make sure a shaft groove is exposed by positioning the small end of the boot in the groove
closest to the constant velocity joint housing.
5. Position the boot clamps.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5797
6. NOTE: Tighten the through-bolt until the tool is in the closed position.
Using the special tool install the two boot clamps.
7. Position the boot clamp on the shaft.
8. Position the inboard boot on the shaft.
9. Position the ball cage on the shaft with the tapered end facing the boot.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5798
10. NOTE: Align the index marks.
Position the inner race on the shaft with the counterbored end facing the boot.
11. Install the snap ring.
12. Lubricate and position the six balls.
^ Use constant velocity joint grease or equivalent provided in the boot kit.
13. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease.
^ Use constant velocity joint grease or equivalent provided in the boot kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5799
14. Make sure a shaft groove is exposed by positioning the small end of the boot in the groove
closest to the constant velocity joint housing.
15. Position the boot clamp on the inboard CV joint housing.
16. Position the inboard CV joint housing on the ball and race assembly.
17. Install the retaining ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5800
18. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.
19. Set the halfshaft assembled length to specification.
20. CAUTION: Do not damage the boot.
Insert a dull screwdriver blade under the boot to release the pressure.
21. NOTE: Tighten the through-bolt until the tool is in the closed position.
Using the special tool, install the two boot clamps.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5801
22. NOTE: Maintain a clean work surface.
Compress the integrated wheel end disconnect on the bench to collapse the vacuum chamber.
23. While the integrated wheel end disconnect is collapsed, install a vacuum cap on the vacuum
port.
24. CAUTION: Do not install the integrated wheel end disconnect in the knuckle. It must be
installed on the outer constant velocity joint housing.
Install the integrated wheel end disconnect on the outer constant velocity joint housing
25. CAUTION: Verify the spline engagement by checking for spline lash before installing the
halfshaft nut.
Install the halfshaft in the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5802
Axle Shaft Assembly: Service and Repair Rear Drive Halfshaft
Removal and Installation
Halfshaft
Special Tool(s)
Removal and Installation
NOTE: This procedure applies to both rear halfshaft assemblies.
1. CAUTION: Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly
is removed from the vehicle. Wheel bearing
damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the rear wheel and tire assembly.
3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating.
Remove and discard the rear axle wheel hub retainer and the washer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5803
4. Using a suitable hub puller, separate the halfshaft from the knuckle.
5. Disconnect the toe link from the rear knuckle.
6. Remove the bolt retaining the knuckle to the lower control arm.
7. Pivot the rear knuckle on the upper control arm bolts and support the knuckle in a raised
position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5804
8. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard
CV joint housing.
CAUTION: Do not allow the splines on inboard CV joint housing to touch the axle shaft oil seal.
NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.
Using the special tool, disengage the inboard CV joint housing from the differential side gear.
9. CAUTION: To prevent damage to the axle shaft oil seal, install the special tool before removing
the inboard CV joint housing from the axle.
Install the special tool after disengaging the CV joint housing from the differential side gears.
10. Remove the halfshaft assembly from the vehicle.
11. Remove and discard the halfshaft retainer circlip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5805
12. CAUTION: To prevent damage to the axle shaft oil seal, install the Halfshaft Seal Protector
before positioning the inboard CV joint housing in
the axle.
CAUTION: Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub
retainer.
CAUTION: Never use power tools to tighten the rear axle wheel hub retainer.
To install, reverse the removal procedure.
Disassembly and Assembly
Halfshaft Joint
Special Tool(s)
Material
Disassembly
1. Remove the halfshaft assembly from the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5806
2. For the inboard CV joint, carry out the following:
1 Remove and discard the boot clamps.
2 Remove the inboard CV joint housing.
3. NOTE: Install the halfshaft in a soft-jaw vise.
For the inboard CV joint, carry out the following: 1
Remove and discard the retainer circlip.
2 Slide the boot away from the CV joint.
4. Using a suitable Maw puller, remove the CV joint.
5. Remove and discard the tri-lobe insert and the boot.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5807
6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or
installed from the inboard CV joint side of the
shaft.
For the outboard CV joint, carry out the following: 1
Remove and discard the boot clamps.
2 Remove and discard the boot.
7. Inspect the grease, packed in the inboard CV joint and the outboard CV joint, for contamination.
Rub some of the grease from each joint between
two fingers. Any gritty feeling indicates contamination. Wash all of the grease from the inboard CV
joint, the inboard CV joint housing, the outboard CV joint and the interconnecting shaft. Thoroughly
dry all of the components and inspect them for wear or damage. Discard the assembly, if
necessary. Only proceed as follows if not discarding the assembly.
8. If necessary, remove and discard the outboard dust seal.
^ Tap uniformly around the seal to separate it from the joint.
9. If necessary, remove and discard the inboard dust seal.
^ Tap uniformly around the seal to separate it from the housing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5808
10. On the inboard end, remove and discard the retainer circlip.
Assembly
1. NOTE: Clean any excess grease from the boot mounting surfaces before installing the boot.
For the outboard CV joint, carry out the following: 1
Slide the boot on the interconnecting shaft.
2 Pack the outboard CV joint with 275 grams (9.7 ounces) of grease.
3 Spread any remaining grease evenly inside the boot.
4 Install the boot by seating it in the groove in the CV joint housing.
2. NOTE: Tighten the through-bolt until the special tool is in the closed position.
Using the special tool, install both boot clamps.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5809
3. If removed, use the special tools to install the dust seal.
4. NOTE: Install the halfshaft in a soft-jaw vise.
NOTE: The lip on the end of the tri-lobe insert must seat against the end of the boot.
For the inboard CV joint, carry out the following: 1
Position the clamp on the interconnecting shaft.
2 Position the boot on the interconnecting shaft.
3 Install the tri-lobe insert.
5. NOTE: One side of the inboard CV joint has a chamfer cut in the edge of joint at the inner
diameter near the splines. Install the inboard CV joint
so that the chamfer faces the outboard end of the halfshaft.
Install the CV joint.
6. Install the retainer circlip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5810
7. NOTE: Clean any excess grease from the boot mounting surfaces before installing the boot.
For the inboard CV joint, carry out the following: 1
Pack the inboard CV joint housing with 325 grams (11.5 ounces) of grease.
2 Spread any remaining grease evenly inside the boot and on the CV joint.
3 Install the inboard CV joint housing, seating the boot in the groove in the housing.
8. Set the halfshaft assembled length to specification.
1 Measure the entire assembly length.
2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length to
specification.
3 Hold the inner joint to prevent the assembled length from changing, and insert a small flat blade
screwdriver between the boot and the joint to equalize the pressure.
9. NOTE: Tighten the through-bolt until the special tool is in the closed position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Front Drive Halfshaft > Page 5811
Using the special tool, install both boot clamps.
10. If removed, use the special tools to install the dust seal.
11. CAUTION: Do not overexpand or twist the circlip during installation.
Install a new retainer circlip.
12. Install the halfshaft assembly in the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking
Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5820
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5821
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5822
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5823
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking
Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5829
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5830
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5831
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5832
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5833
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-19-3 Date: 080929
Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5834
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5835
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5836
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5837
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Technical Service Bulletin # 08-19-3 Date: 080929
Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5838
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5839
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE
SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL
SEPARATE, RESULTING IN THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5840
Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor
Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5841
Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Specifications
Wheel Bearing: Specifications
Wheel bearing-to-knuckle bolts
.............................................................................................................................................................
200 Nm (148 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Specifications > Page 5845
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp 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.
3. If the wheel (hub) is loose or does not rotate freely, install a new wheel hub.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position.
2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel and tire
assembly.
4. Remove the bolt and detach the retainers.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5848
6. Remove the brake disc.
7. Remove the dust cap.
8. Remove and discard the nut.
9. Remove the bolts and the wheel bearing and hub assembly.
10. CAUTION: If the original wheel bearing and hub is being reinstalled, make sure to install a new
O-ring.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5849
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating.
Remove and discard the rear axle wheel hub retainer and the washer
4. Using a suitable hub puller, separate the outboard CV joint from the wheel hub.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5850
6. Remove the brake disc.
7. Disconnect the wheel speed sensor electrical connector and detach the retainer.
8. Remove the bolt and detach the retainers.
9. Remove the bolts, the wheel bearing and the wheel speed sensor as an assembly.
^ Route the sensor wiring through the access hole in the brake shield.
^ Discard the bolts.
10. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Rear axle wheel hub retainer ...............................................................................................................
................................................... 345 Nm (254 lb. ft.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock
Solenoid > Component Information > Locations
Wheel Hub Lock Solenoid: Locations
INTEGRATED WHEEL ENDS SOLENOID
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock
Solenoid > Component Information > Locations > Page 5858
Wheel Hub Lock Solenoid: Diagrams
INTEGRATED WHEEL ENDS SOLENOID
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation
Universal Joint: Service and Repair Removal and Installation
Universal Joints
The universal joint (U-joint) connects to the drive axle of the driveshaft and allows for up and down
movement of the axle. The U-joint is lubricated for the life of the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5864
Universal Joint: Service and Repair Disassembly and Assembly
Driveshaft Universal Joint Single Cardan
Special Tool(s)
Disassembly
1. Remove the driveshaft.
2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or a similar holding fixture.
Carefully place the driveshaft on a suitable workbench.
3. NOTE: Index the driveshaft components relative to the driveshaft tube. Make sure all
components are reassembled in the same relationship to
maintain correct balance.
Index the driveshaft and driveshaft components.
4. Position the special tool in a vise.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5865
5. Remove the snap rings from the universal joint.
6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all
the way.
Remove the driveshaft flange yoke. 1
Position the driveshaft flange in the special tool.
2 Press out the bearing cup.
3 Rotate the driveshaft flange yoke.
4 Press on the spider to remove the remaining bearing cup.
5 Remove the driveshaft flange yoke.
7. Repeat the previous step to remove the remaining bearing cups and spider from the driveshaft.
8. Clean the yoke area at the end of the driveshaft and flange yoke.
Assembly
NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not use
components from other universal joints.
1. Clamp the special tool in a vise.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Installation > Page 5866
2. Install a new bearing cup.
1 Start a new bearing cup into the driveshaft yoke.
2 Position a new spider in the driveshaft yoke.
3 Install the driveshaft into the special tool.
4 Press the bearing cup below the yoke surface.
3. Remove the driveshaft from the special tool and install the snap ring. 4. Repeat the previous
steps to install the remaining bearing cups.
5. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer.
Check the universal joint for freedom of movement.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
TORQUE SPECIFICATIONS
Flexplate Bolts .....................................................................................................................................
..................................................... 80 Nm (59 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5870
Flex Plate: Service and Repair
Flexplate
Removal and Installation
1. Remove the transmission.
2. Remove the 8 bolts and the flexplate.
^ To install, tighten to 80 Nm (59 ft. lbs.) in the sequence shown.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Shift Indicator > Component Information > Service and Repair
Shift Indicator: Service and Repair
SELECTOR LEVER INDICATOR BULB
Removal and Installation
1. Push down the selector lever boot.
2. Push down the selector lever collar.
3. Remove the selector lever knob screw.
- Remove the selector lever knob.
4. Detach the selector lever indicator bezel.
- Disconnect the electrical connector.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and
Operation
Power Take-Off: Description and Operation
POWER TAKE-OFF (PTO) SWITCH AND CIRCUITS
The PTO circuit is used by the PCM to disable some of the OBD Monitors during PTO operation.
The PTO switch is normally open. When the PTO unit is activated, the PTO switch is closed and
battery voltage is supplied to the PTO input circuit. This indicates to the PCM that an additional
load is being applied to the engine.
When the PTO unit is activated, the PCM disables some OBD monitors, which may not function
reliably during PTO operation. Without the PTO circuit information to the PCM, false diagnostic
trouble codes (DTCs) may be set during PTO operation. Prior to an Inspection/Maintenance test,
the vehicle will have to be operated with the PTO disengaged long enough to successfully
complete the OBD Monitors.
PTO CIRCUITS DESCRIPTION
The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM.
The PTO engage circuit is used when the operator is requesting the PCM to check the needed
inputs required to initiate the PTO engagement.
The PTO RPM circuit is used while the operator request additional engine RPM for PTO operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair
Control Module: Service and Repair
Four-Wheel Drive (4WD) Control Module
Removal and Installation
NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module
(PCM) and is not serviced separately.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations
Four Wheel Drive Selector Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 5887
View 151-1 (Engine Compartment)
The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1
located in the engine compartment. LH side, front.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to
High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to
High Relay > Page 5890
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer
Case Low to High Relay
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer
Case Low to High Relay > Page 5893
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer
Case Low to High Relay > Page 5894
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer
Case Low to High Relay > Page 5895
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 5904
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive. The operator of the vehicle controls. the position of the TCS.
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch
in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission
Control (TC) Switch - Column Shift
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift
Transmission Control (TC) Switch - Column Shift
Removal and Installation
NOTE: The Transmission Control (TC) switch is not replaceable. If a new TC switch is required,
install a new transmission selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission
Control (TC) Switch - Column Shift > Page 5910
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift
Transmission Control (TC) Switch - Floor Shift
Removal and Installation
NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a
new selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5914
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5915
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5916
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5917
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5918
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor > Page 5923
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5926
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5927
Transmission Speed Sensor: Service and Repair
Speed Sensors
NOTE: Only remove the affected sensor.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5932
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5933
Four Wheel Drive Selector Switch: Description and Operation
FOUR-WHEEL DRIVE (4WD) MODE SWITCH
Typical 4WD Switch
The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to
adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Service and Repair
Control Module: Service and Repair
Four-Wheel Drive (4WD) Control Module
Removal and Installation
NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module
(PCM) and is not serviced separately.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 5942
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Page 5943
Fluid - Transfer Case: Service and Repair
Transfer Case Draining and Filling
Special Tool(s)
Material
1. Remove the drain plug and drain the fluid. Clean the drain plug and the drain plug area. Apply
thread sealant to the drain plug threads, then install
the drain plug.
2. Clean the area around the fill plug. Remove the fill plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Page 5944
3. CAUTION: Incorrect fluid fill can result in transfer case failure.
Using the special tool, fill the transfer case to specification. ^
The fluid must be just below the fill plug hole. Fill the case until the fluid slowly flows over the fill
plug threads. Clean the fluid from the fill plug area.
4. Apply thread sealant to the fill plug threads, then install the fill plug.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Locations
Four Wheel Drive Selector Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Locations > Page 5948
View 151-1 (Engine Compartment)
The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1
located in the engine compartment. LH side, front.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Transfer Case Low to High Relay > Page 5951
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay > Page 5954
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay > Page 5955
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay > Page 5956
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5960
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5961
Four Wheel Drive Selector Switch: Description and Operation
FOUR-WHEEL DRIVE (4WD) MODE SWITCH
Typical 4WD Switch
The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to
adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Service and Repair
Control Module: Service and Repair
Four-Wheel Drive (4WD) Control Module
Removal and Installation
NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module
(PCM) and is not serviced separately.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Locations
Four Wheel Drive Selector Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Locations > Page 5969
View 151-1 (Engine Compartment)
The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1
located in the engine compartment. LH side, front.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay > Page 5972
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page
5975
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page
5976
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page
5977
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair
Seals and Gaskets: Service and Repair
Transfer Case Rear Output Shaft Oil Seal
Special 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. Failure to do this will result is unexpected inflation or deflation of the vehicle during these
operations.
Position the vehicle on a hoist.
2. NOTE: Index-mark the rear driveshaft yoke and pinion flange to maintain initial driveshaft
balance during installation.
Remove the rear driveshaft.
3. Using a suitable tool, remove the oil seal.
Installation
1. To install, reverse the removal procedure.
^ Using the special tool, install the oil seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations > Page 5985
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations > Page 5986
Four Wheel Drive Selector Switch: Description and Operation
FOUR-WHEEL DRIVE (4WD) MODE SWITCH
Typical 4WD Switch
The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to
adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Service and Repair
Pressure Regulating Solenoid: Service and Repair
Electronic Pressure Control (EPC) Solenoid
Special Tool(s)
Removal
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends.
Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame
from the solenoids.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the
transmission fluid pan and filter.
3. Disconnect the molded lead frame from the solenoids.
1 Disconnect the shift solenoid SSA and SSB.
2 Disconnect the Torque Converter Clutch (TCC).
3 Disconnect the Electronic Pressure Control (EPC) solenoid.
4 Disconnect the bulkhead interconnector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Service and Repair > Page 5993
4. Remove the Electronic Pressure Control (EPC) solenoid.
1 Remove the EPC solenoid bolt.
2 Remove the EPC solenoid.
Installation
1. Install the Electronic Pressure Control (EPC) solenoid.
1 Install the EPC solenoid.
2 Install the EPC solenoid bolt.
2. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and
not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a
good contact, install a new lead frame.
3. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the
connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in
place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make
sure that the terminals pass fully through the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Service and Repair > Page 5994
connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the
connector in place. Make sure that the terminals pass fully through the connector slots.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair
Shift Indicator: Service and Repair
SELECTOR LEVER INDICATOR BULB
Removal and Installation
1. Push down the selector lever boot.
2. Push down the selector lever collar.
3. Remove the selector lever knob screw.
- Remove the selector lever knob.
4. Detach the selector lever indicator bezel.
- Disconnect the electrical connector.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Service and Repair
Control Module: Service and Repair
Four-Wheel Drive (4WD) Control Module
Removal and Installation
NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module
(PCM) and is not serviced separately.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Locations
Four Wheel Drive Selector Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Locations > Page 6008
View 151-1 (Engine Compartment)
The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1
located in the engine compartment. LH side, front.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Transfer Case Low to High Relay > Page 6011
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6014
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6015
Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6016
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description
and Operation
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations >
Page 6025
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive. The operator of the vehicle controls. the position of the TCS.
Transmission Control Indicator Lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch
in this section.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Service and Repair > Transmission Control (TC) Switch - Column Shift
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift
Transmission Control (TC) Switch - Column Shift
Removal and Installation
NOTE: The Transmission Control (TC) switch is not replaceable. If a new TC switch is required,
install a new transmission selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 6031
Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift
Transmission Control (TC) Switch - Floor Shift
Removal and Installation
NOTE: The transmission control (+/-) switch is not serviced. If a new switch is required, install a
new selector lever assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6035
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6036
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tool(s)
Removal
NOTE: Manual shift lever must be in the NEUTRAL position.
1. With the vehicle in NEUTRAL, position it on a hoist.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6037
2. Disconnect the digital TR electrical connector.
3. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage.
Disconnect the manual control lever shift control cable.
4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse the nut.
Remove the manual control lever. 1
Remove the nut.
2 Remove the lever.
5. Remove the digital TR sensor bolts and the digital TR sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6038
1. Install the digital TR sensor and loosely install the bolts.
2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Tighten the bolts.
4. Install the manual control lever.
1 Install the lever.
2 Install a new nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6039
5. With the manual control lever in NEUTRAL, connect the shift control cable.
6. Install the digital TR electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Output Shaft Speed (OSS) Sensor
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Output Shaft Speed (OSS) Sensor > Page 6044
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 6047
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 6048
Transmission Speed Sensor: Service and Repair
Speed Sensors
NOTE: Only remove the affected sensor.
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 6053
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 6054
Four Wheel Drive Selector Switch: Description and Operation
FOUR-WHEEL DRIVE (4WD) MODE SWITCH
Typical 4WD Switch
The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to
adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 6061
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor > Page 6064
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6068
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6069
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
NOTE: When installing a new module, it must be calibrated and configured (either by
download/upload or uploading the as-built data method).
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery.
2. Disconnect the ABS module electrical connector.
3. Remove the 3 bolts and the ABS module. 4. To install, reverse the removal procedure
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)
Removal and Installation
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery.
2. Disconnect the anti-lock brake system (ABS) 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, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instruction may result in personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific
design and only authorized parts should be used when installing new inlet brake tubes.
NOTE: Plug each open port to prevent brake fluid from spilling.
Disconnect the hydraulic brake line nuts.
4. Remove the 3 bolts and the hydraulic control unit (HCU).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6073
5. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Stability Control Sensor Cluster
Removal and Installation
NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the
yaw rate sensor, stability control sensor cluster.
1. Remove the front floor console.
2. Remove the 2 bolts and the stability control sensor cluster.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Removal and Installation
1. Disconnect the battery.
2. Remove the 2 bolts and the steering wheel rotation sensor.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations
View 151-24 (Centre Console)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 6083
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Right Front
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Right Front > Page 6088
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Right Front > Page 6089
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 6092
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 6093
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 6094
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor-Front
Wheel Speed Sensor-Front
Removal and Installation
1. NOTE: If equipped, turn the air suspension switch to the OFF position.
With the vehicle in NEUTRAL, position it on a hoist
2. Disconnect the wheel speed sensor electrical connector.
3. Remove the bolt and the retainers.
4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front > Page 6097
5. Remove the brake disc.
6. Remove the bolt and the front wheel speed sensor. 7. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front > Page 6098
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Removal and Installation
1. Remove the parking brake shoes.
2. Disconnect the wheel speed sensor wire from the retaining clips.
3. Remove the bolt and the rear wheel speed sensor. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Locations > Page 6102
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Locations > Page 6103
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Removal and Installation
NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the
yaw rate sensor, stability control sensor cluster.
1. Remove the front floor console.
2. Remove the 2 bolts and the stability control sensor cluster.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Customer Interest for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist
Brake Bleeding: Customer Interest Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist
Brake Bleeding: All Technical Service Bulletins Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6117
Brake Bleeding: By Symptom
Technical Service Bulletin # 05-26-21 Date: 051231
Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6118
Disclaimer
Technical Service Bulletin # 05-26-21 Date: 051231
Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6119
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6120
Brake Bleeding: Service and Repair
Brake System Bleeding
Special Tools And Equipment
Special Tool(s)
Material
Material
Master Cylinder, In Vehicle
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. 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 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6121
2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the
brake master cylinder reservoir with brake fluid. 3. Have an assistant pump the brake pedal until
clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and
install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows:
1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2.
Loosen the 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.
Four Wheel Anti-Lock Brake System (4WABS)
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: This procedure must be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control
unit (HCU) has been installed new.
NOTE: One conventional pressure bleed cycle consists of advancing the brake pedal to its
depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into
the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal.
NOTE: Performing the diagnostic program routine drives entrapped air from the otherwise
inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the
brakes). Subsequent 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 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6122
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 diagnostic tool.
Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash and follow the diagnostic tool instructions.
7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal
feels spongy, repeat the diagnostic tool service bleed procedure.
Gravity
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6123
with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic
system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When a new brake master cylinder has been installed or the system has been emptied, or
partially emptied, it should be primed to prevent air from getting into the system.
1. Fill the brake master cylinder reservoir with brake fluid.
2. Bleed the rear disc brake calipers.
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.
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6124
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.
Manual
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH rear disc brake caliper bleeder screw
and submerge the free end of the tube in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have
an assistant maintain pressure on the brake
pedal while tightening the RH rear disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6125
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.
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.
Pressure
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6126
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid
to complete the bleeding operation.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose
to the fitting on the adapter.
3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH rear disc brake caliper bleeder screw
and submerge the free end of the tube in a container partially filled with clean brake fluid.
4. Open the valve on the bleeder tank.
5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid
flows, then tighten rear disc brake caliper bleeder
screw and remove the rubber hose.
6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to
the RH front disc brake caliper ending with the LH
front disc brake caliper.
7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the
adapter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Page 6127
8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap.
Master Cylinder, Bench
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with
specified brake fluid.
^ Use clean brake fluid.
2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3.
Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles.
4. Remove the short brake tubes.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6132
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6133
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6134
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6135
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6136
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6137
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6138
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6139
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6140
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6141
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6142
Brake Pedal Assy: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6143
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6144
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6145
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6146
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6147
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6148
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6149
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6150
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6151
Brake Pedal Assy: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
127-1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6152
127-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6153
127-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket-Adjustable
Brake Pedal Assy: Service and Repair Brake Pedal and Bracket-Adjustable
Brake Pedal and Bracket-Adjustable
Removal and Installation
1. CAUTION: The brake pedal and the accelerator pedal must be in the same position when
installing a new cable or a new pedal. The pedals must
be all the way forward or all the way rearward.
Disconnect the battery.
2. CAUTION: The booster pushrod must be installed with the pushrod offset, if present, pointing
downward.
Remove the stoplight switch self-lock pin and slide the stoplight switch, booster push rod and the
bushing off the brake pedal pin.
3. Remove the accelerator pedal-to-brake pedal cable.
4. CAUTION: Do not install the speed control deactivator switch after detaching it from the brake
pedal bracket.
Turn the speed control deactivation switch counterclockwise and detach it from the brake pedal
bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket-Adjustable > Page 6156
5. Remove the bulkhead sound insulator.
6. Remove the 4 brake pedal bracket nuts.
7. Remove the brake pedal bracket bolts, and remove the brake pedal and bracket. 8. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket-Adjustable > Page 6157
Brake Pedal Assy: Service and Repair Brake Pedal and Bracket-Fixed
Brake Pedal and Bracket-Fixed
Removal and Installation
1. CAUTION: The booster pushrod must be installed with the pushrod offset, if present, pointing
downward.
Remove the stoplight switch self-lock pin and slide the stoplight switch, booster push rod and the
bushing off the brake pedal pin.
2. CAUTION: Do not install the speed control deactivation switch after detaching it from the brake
pedal bracket.
Turn the speed control deactivation switch counterclockwise and detach it from the brake pedal
bracket.
3. Remove the bulkhead sound insulator.
4. Remove the 4 brake pedal bracket nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket-Adjustable > Page 6158
5. Remove the brake pedal bracket bolts, and remove the brake pedal and bracket. 6. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder
When Braking
Brake Caliper: Customer Interest Brakes - Roughness or Shudder When Braking
TSB 06-12-5
06/26/06
BRAKE SHUDDER
FORD: 2004-2006 Expedition
LINCOLN: 2004-2006 Navigator
This article supersedes TSB 06-3-17 to add a production fix date.
ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006
may experience repeat front brake roughness and / or shudder while braking.
ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors
and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or
replace the rotors as appropriate.
SERVICE PROCEDURE
1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor,
between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd),
replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03
for front rotor and caliper replacement procedure.
NOTE
REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE
CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE
PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE
INSTALLED AS A UNIT WITHOUT DISASSEMBLY.
2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car
brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond
machinable thickness, replace the front rotors.
NOTE
DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE
PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL
IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING
DISTANCE AND/OR BRAKE EFFECTIVENESS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder
When Braking > Page 6168
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061205A 2004-2006 0.9 Hr.
Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT)
061205B 2004-2006 1.5 Hrs.
Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2B120 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness
or Shudder When Braking
Brake Caliper: All Technical Service Bulletins Brakes - Roughness or Shudder When Braking
TSB 06-12-5
06/26/06
BRAKE SHUDDER
FORD: 2004-2006 Expedition
LINCOLN: 2004-2006 Navigator
This article supersedes TSB 06-3-17 to add a production fix date.
ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006
may experience repeat front brake roughness and / or shudder while braking.
ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors
and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or
replace the rotors as appropriate.
SERVICE PROCEDURE
1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor,
between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd),
replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03
for front rotor and caliper replacement procedure.
NOTE
REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE
CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE
PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE
INSTALLED AS A UNIT WITHOUT DISASSEMBLY.
2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car
brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond
machinable thickness, replace the front rotors.
NOTE
DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE
PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL
IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING
DISTANCE AND/OR BRAKE EFFECTIVENESS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness
or Shudder When Braking > Page 6174
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061205A 2004-2006 0.9 Hr.
Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT)
061205B 2004-2006 1.5 Hrs.
Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2B120 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front
Brake Caliper: Service and Repair Front
Brake Caliper Removal and Installation
Brake Caliper
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. 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. Remove the brake pads.
3. 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.
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. Failure to follow these instructions may result in personal injury.
Disconnect the front brake hose. ^
Use new copper washers to connect the front brake hose.
5. Remove the disc brake caliper bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6177
6. Measure the brake disc thickness.
^ Install a new brake disc (1125) if not within specification.
7. Inspect the disc brake caliper for leaks.
^ If leaks are found, the brake caliper must be disassembled.
8. Bleed the brake system. 9. To install, reverse the removal procedure.
Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
Removal and Installation
1. Remove the brake pads. 2. Remove the brake caliper anchor plate.
1. Remove the brake caliper anchor plate bolts. 2. Remove the brake caliper anchor plate.
3. To install, reverse the removal procedure.
Brake Caliper Disassembly and Assembly
DISASSEMBLY AND ASSEMBLY
Brake Caliper
Material
Material
Disassembly
1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3.
Secure the disc brake caliper in a vise. 4. Remove the caliper pistons (2196).
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6178
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.
1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with brake fluid. 2. Place
the brake caliper in a vise.
3. Install the caliper pistons.
1. Install the piston seal. 2. Install the piston boot on the brake caliper.
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.
Insert the piston into the disc brake caliper bore. ^
Place the piston squarely against the dust boot.
^ While applying shop air to the fluid port in the disc brake caliper, push the piston squarely into the
bore.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6179
4. Install the disc brake caliper.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6180
Brake Caliper: Service and Repair Rear
Caliper Disassembly and Assembly
DISASSEMBLY AND ASSEMBLY
Caliper
Special Tools And Equipment
Special Tool(s)
Material
Material
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 or
piston is excessively scored or corroded, install a new rear disc brake caliper.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6181
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
1. Lubricate the following with brake fluid.
^ Cylinder bore.
^ Piston seal.
^ Caliper piston.
^ Dust boot.
2. Install the piston seal.
3. Using the special tools, install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
CAUTION: Insert the caliper piston squarely into the caliper bore.
Install the caliper piston. 1. Place the brake caliper in a vise. 2. Place the piston squarely against
the dust boot. 3. While applying shop air into the brake caliper, push the piston squarely into the
brake caliper bore.
5. Install the rear disc brake caliper.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6182
Brake Caliper Removal and Installation
Brake Caliper
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. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal injury.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Remove the bolt and disconnect the hose. ^
Remove and discard the copper washers.
3. Remove the brake pads.
4. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist
Brake Pad: Customer Interest Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-26-21 > Dec > 05 > Brakes - Unintended
Brake Assist
Brake Pad: All Technical Service Bulletins Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Front
General Specifications, Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Front > Page 6198
General Specifications, Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front
Brake Pad: Service and Repair Front
Brake Pads
Material
Material
Removal
1. 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.
If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir
until it is half filled.
2. Remove the wheel and tire assembly.
3. Inspect the brake pads for wear or contamination.
4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring
off the brake caliper. Do not install a damaged
anchor housing spring.
Remove the anchor housing spring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6201
5. NOTE: Verify if the anchor housing spring has 1 end with 2 tabs. If yes, the LH side anchor
housing spring must be installed with the 2-tabbed
end in the upper brake caliper cavity.
For the LH brake caliper, release the lower portion of the anchor housing spring. ^
Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor
housing spring to remove it from the lower brake caliper cavity.
6. Rotate the spring upward then remove it from the brake caliper.
7. NOTE: On the RH side, the anchor housing spring must be installed with the 2-tabbed end in the
lower brake caliper cavity. The illustration
below shows the anchor housing spring end with 2 tabs.
For RH brake caliper, release the upper portion of the anchor housing spring. ^
Apply force at the center of the anchor housing spring and pull outward at the top of the anchor
housing spring to remove it from the upper brake caliper cavity.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6202
8. Rotate the spring downward then remove it from the brake caliper.
9. NOTE: Do not allow the brake caliper to hang from the brake hose.
Remove the brake caliper. 1. Remove the zero-drag spring. 2. Remove and discard the brake
caliper-to-anchor plate bolts, guide pins and boots.
10. Remove the brake pads from the brake caliper.
11. NOTE: Use a wood block or used brake pad to protect the brake caliper piston boots.
Compress the brake caliper pistons.
12. Measure the brake disc thickness.
^ Install a new brake disc if it is not within specification.
Installation
1. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads
attach. 2. Install new brake hardware as follows:
^ Install the guide pin bushings into the caliper bores.
^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads.
^ Push the guide pins into the bushing.
3. Install the inboard brake pad into the brake caliper. 4. Remove the protective paper from the
outboard brake pad and install it into the brake caliper. 5. Install the brake caliper on the brake disc.
6. Tighten the guide pins and install the dust caps. 7. Install the zero-drag spring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6203
NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first.
8. Install the anchor housing spring.
1. Insert tab of the anchor housing spring into the brake caliper cavity. 2. Twist tab into the brake
caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity).
9. Rotate the anchor housing spring and position the upper portion onto the anchor plate.
10. Position the other anchor housing spring portion onto the brake caliper anchor plate. 11. Push
down and inward until the upper and lower ends of the anchor housing spring are latched and
seated in the brake caliper cavities.
12. NOTE: The latch MUST be positioned as shown.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6204
Verify that the anchor housing spring is correctly latched.
13. Install the wheel and tire assembly. 14. Apply the brake several times to verify correct brake
operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6205
Brake Pad: Service and Repair Rear
Brake Pads
Removal and Installation
1. Using a clear suction device, remove brake fluid in the master cylinder reservoir until the
reservoir is half full.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Remove the wheel and tire assembly.
3. CAUTION: Install new pads if worn to or past the specified thickness above the metal backing
plate. Install new pads in complete axle sets.
Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification.
4. Remove the anchor housing spring.
^ Squeeze at the center of the spring until it unlatches from the brake caliper at both ends.
^ Rotate the spring, then remove it from the caliper housing.
5. Remove the caps and brake caliper bolts.
6. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose.
NOTE: It is not necessary to remove the rear wheel brake hose when carrying out this procedure.
Remove the caliper and the brake pads.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6206
7. Using a suitable clamp, press the piston into the caliper.
8. CAUTION: If machining is necessary, use a hub-mount brake lathe to machine the rear brake
disc.
Inspect the brake disc. If it is scored it must be resurfaced.
9. NOTE: Also, resurface the rear brake disc if a test drive has identified vibration transmitted
through the steering wheel, seat, or brake pedal while
braking.
Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond
specification.
10. To install, reverse the removal procedure.
11. Install the anchor housing spring.
1. Insert the upper anchor housing spring end into the brake caliper cavity. 2. Rotate the anchor
housing spring and position the lower arm onto the anchor plate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6207
12. Position the upper arm onto the anchor plate, then press down and inward until it is correctly
seated and latched into the brake caliper cavities.
13. NOTE: The latch MUST be positioned as shown.
Verify that the anchor housing spring is correctly latched.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes - Roughness or
Shudder When Braking
Brake Rotor/Disc: Customer Interest Brakes - Roughness or Shudder When Braking
TSB 06-12-5
06/26/06
BRAKE SHUDDER
FORD: 2004-2006 Expedition
LINCOLN: 2004-2006 Navigator
This article supersedes TSB 06-3-17 to add a production fix date.
ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006
may experience repeat front brake roughness and / or shudder while braking.
ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors
and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or
replace the rotors as appropriate.
SERVICE PROCEDURE
1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor,
between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd),
replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03
for front rotor and caliper replacement procedure.
NOTE
REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE
CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE
PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE
INSTALLED AS A UNIT WITHOUT DISASSEMBLY.
2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car
brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond
machinable thickness, replace the front rotors.
NOTE
DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE
PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL
IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING
DISTANCE AND/OR BRAKE EFFECTIVENESS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes - Roughness or
Shudder When Braking > Page 6216
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061205A 2004-2006 0.9 Hr.
Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT)
061205B 2004-2006 1.5 Hrs.
Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2B120 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking
Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness or Shudder When Braking
TSB 06-12-5
06/26/06
BRAKE SHUDDER
FORD: 2004-2006 Expedition
LINCOLN: 2004-2006 Navigator
This article supersedes TSB 06-3-17 to add a production fix date.
ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006
may experience repeat front brake roughness and / or shudder while braking.
ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors
and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or
replace the rotors as appropriate.
SERVICE PROCEDURE
1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor,
between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd),
replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03
for front rotor and caliper replacement procedure.
NOTE
REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE
CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE
PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE
INSTALLED AS A UNIT WITHOUT DISASSEMBLY.
2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car
brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond
machinable thickness, replace the front rotors.
NOTE
DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE
PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL
IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING
DISTANCE AND/OR BRAKE EFFECTIVENESS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking > Page 6222
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061205A 2004-2006 0.9 Hr.
Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT)
061205B 2004-2006 1.5 Hrs.
Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2B120 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Front
General Specifications, Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Front > Page 6225
General Specifications, Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 and Installation
Brake Disc
Removal and Installation
1. Remove the brake caliper anchor plate.
2. Remove the brake disc. 3. To install, reverse the removal procedure.
Brake Disc Shield Removal and Installation
Brake Disc Shield
Removal and Installation
1. Remove the brake disc.
2. Remove the brake disc shield.
1. Remove the brake disc shield screws. 2. Remove the brake disc shield.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6228
Brake Rotor/Disc: Service and Repair Rear
Brake Disc
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. NOTE: When removing the rear disc brake caliper in this procedure, it is not necessary to
disconnect the rear wheel brake hose.
Remove the brake caliper anchor plate bolts.
3. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose.
Remove the anchor plate and caliper as an assembly.
4. NOTE: If the brake disc binds on the parking brake shoe, remove the adjustment hole access
plug and contract the parking brake shoe.
Remove the brake disc.
5. CAUTION: If machining is necessary use a hub-mount brake lathe to machine the rear brake
disc.
NOTE: Inspect the brake disc. If it is scored, it must be resurfaced. Also, resurface the rear brake
disc if a test drive has identified vibration
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6229
transmitted through the steering wheel, seat or brake pedal while braking.
Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond
specification.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6230
Brake Rotor/Disc: Service and Repair Brake Disc Machining
Brake Disc Machining
Special Tools And Equipment
Special Tool(s)
Material
Material
CAUTION: Do not use a bench lathe to machine the brake discs.
NOTE: Read the entire operating manual and view the video shipped with the lathe before
installing, operating, or repairing the lathe.
NOTE: If the thickness of the brake disc is less than the minimum thickness to machine
specification, install a new brake disc. This will make sure that the brake disc will be above
minimum thickness after machining.
NOTE: Do not machine new brake discs.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct
adjustment of the on-vehicle brake lathe will make sure that these dimensions are within
specifications.
1. NOTE: It is not necessary to disconnect the brake line from the brake caliper.
Position the brake caliper and brake caliper anchor bracket aside.
2. For vehicles with a 2-piece brake disc and hub assembly:
1. Mark the brake disc and the wheel stud for correct indexing during re-assembly. 2. Remove the
brake disc from the hub.
3. CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective
finishes from the wheel or metal from the
mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout.
Remove corrosion from the wheel mounting surface, both disc mounting surfaces, and hub
mounting surface.
4. Align the match marks and install the brake disc on the hub.
3. Machine the brake disc using an on-car brake lathe.
1. Install the hub adapter and silencer belt, if necessary. 2. Install the cutting lathe. 3. If the lathe is
not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR)
target is 0.000 mm (0.000
inch), maximum is 0.08 mm (0.003 inch).
4. Center the cutting head, adjust the cutting bits, and install the chip deflector.
5. NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause the bit to heat up and wear
faster. Heavier cuts will cause poor brake disc surface finish.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 6231
Machine the brake disc.
6. Remove the lathe and, if installed, the silencer belt. 7. Remove the hub adapter.
4. Remove the metal shavings. 5. For vehicles with a 2-piece brake disc and hub assembly:
1. Remove the brake disc from the hub. 2. Remove metal shavings from the hub, the brake disc
mounting surfaces and from the ABS sensors. 3. Apply anti-seize lubricant to the hub mounting
surface to prevent corrosion. 4. Align the match marks and install the brake disc on the hub.
6. NOTE: It is not required to install new brake pads if friction material properties are within
guidelines.
Install the brake caliper and brake caliper anchor bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Customer Interest for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake
Assist
Brake Bleeding: Customer Interest Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes Unintended Brake Assist
Brake Bleeding: All Technical Service Bulletins Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6246
Brake Bleeding: By Symptom
Technical Service Bulletin # 05-26-21 Date: 051231
Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6247
Disclaimer
Technical Service Bulletin # 05-26-21 Date: 051231
Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6248
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6249
Brake Bleeding: Service and Repair
Brake System Bleeding
Special Tools And Equipment
Special Tool(s)
Material
Material
Master Cylinder, In Vehicle
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. 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 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6250
2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the
brake master cylinder reservoir with brake fluid. 3. Have an assistant pump the brake pedal until
clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and
install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows:
1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2.
Loosen the 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.
Four Wheel Anti-Lock Brake System (4WABS)
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: This procedure must be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control
unit (HCU) has been installed new.
NOTE: One conventional pressure bleed cycle consists of advancing the brake pedal to its
depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into
the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal.
NOTE: Performing the diagnostic program routine drives entrapped air from the otherwise
inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the
brakes). Subsequent 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 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6251
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 diagnostic tool.
Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash and follow the diagnostic tool instructions.
7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal
feels spongy, repeat the diagnostic tool service bleed procedure.
Gravity
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6252
with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic
system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When a new brake master cylinder has been installed or the system has been emptied, or
partially emptied, it should be primed to prevent air from getting into the system.
1. Fill the brake master cylinder reservoir with brake fluid.
2. Bleed the rear disc brake calipers.
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.
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6253
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.
Manual
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH rear disc brake caliper bleeder screw
and submerge the free end of the tube in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have
an assistant maintain pressure on the brake
pedal while tightening the RH rear disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6254
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.
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.
Pressure
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6255
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid
to complete the bleeding operation.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose
to the fitting on the adapter.
3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH rear disc brake caliper bleeder screw
and submerge the free end of the tube in a container partially filled with clean brake fluid.
4. Open the valve on the bleeder tank.
5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid
flows, then tighten rear disc brake caliper bleeder
screw and remove the rubber hose.
6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to
the RH front disc brake caliper ending with the LH
front disc brake caliper.
7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the
adapter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Page 6256
8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap.
Master Cylinder, Bench
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with
specified brake fluid.
^ Use clean brake fluid.
2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3.
Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles.
4. Remove the short brake tubes.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking
Brake Caliper: Customer Interest Brakes - Roughness or Shudder When Braking
TSB 06-12-5
06/26/06
BRAKE SHUDDER
FORD: 2004-2006 Expedition
LINCOLN: 2004-2006 Navigator
This article supersedes TSB 06-3-17 to add a production fix date.
ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006
may experience repeat front brake roughness and / or shudder while braking.
ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors
and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or
replace the rotors as appropriate.
SERVICE PROCEDURE
1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor,
between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd),
replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03
for front rotor and caliper replacement procedure.
NOTE
REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE
CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE
PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE
INSTALLED AS A UNIT WITHOUT DISASSEMBLY.
2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car
brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond
machinable thickness, replace the front rotors.
NOTE
DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE
PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL
IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING
DISTANCE AND/OR BRAKE EFFECTIVENESS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking > Page 6265
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061205A 2004-2006 0.9 Hr.
Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT)
061205B 2004-2006 1.5 Hrs.
Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2B120 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes
- Roughness or Shudder When Braking
Brake Caliper: All Technical Service Bulletins Brakes - Roughness or Shudder When Braking
TSB 06-12-5
06/26/06
BRAKE SHUDDER
FORD: 2004-2006 Expedition
LINCOLN: 2004-2006 Navigator
This article supersedes TSB 06-3-17 to add a production fix date.
ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006
may experience repeat front brake roughness and / or shudder while braking.
ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors
and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or
replace the rotors as appropriate.
SERVICE PROCEDURE
1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor,
between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd),
replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03
for front rotor and caliper replacement procedure.
NOTE
REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE
CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE
PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE
INSTALLED AS A UNIT WITHOUT DISASSEMBLY.
2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car
brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond
machinable thickness, replace the front rotors.
NOTE
DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE
PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL
IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING
DISTANCE AND/OR BRAKE EFFECTIVENESS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes
- Roughness or Shudder When Braking > Page 6271
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061205A 2004-2006 0.9 Hr.
Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT)
061205B 2004-2006 1.5 Hrs.
Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A,
2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2B120 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front
Brake Caliper: Service and Repair Front
Brake Caliper Removal and Installation
Brake Caliper
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. 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. Remove the brake pads.
3. 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.
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. Failure to follow these instructions may result in personal injury.
Disconnect the front brake hose. ^
Use new copper washers to connect the front brake hose.
5. Remove the disc brake caliper bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6274
6. Measure the brake disc thickness.
^ Install a new brake disc (1125) if not within specification.
7. Inspect the disc brake caliper for leaks.
^ If leaks are found, the brake caliper must be disassembled.
8. Bleed the brake system. 9. To install, reverse the removal procedure.
Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
Removal and Installation
1. Remove the brake pads. 2. Remove the brake caliper anchor plate.
1. Remove the brake caliper anchor plate bolts. 2. Remove the brake caliper anchor plate.
3. To install, reverse the removal procedure.
Brake Caliper Disassembly and Assembly
DISASSEMBLY AND ASSEMBLY
Brake Caliper
Material
Material
Disassembly
1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3.
Secure the disc brake caliper in a vise. 4. Remove the caliper pistons (2196).
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6275
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.
1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with brake fluid. 2. Place
the brake caliper in a vise.
3. Install the caliper pistons.
1. Install the piston seal. 2. Install the piston boot on the brake caliper.
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.
Insert the piston into the disc brake caliper bore. ^
Place the piston squarely against the dust boot.
^ While applying shop air to the fluid port in the disc brake caliper, push the piston squarely into the
bore.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6276
4. Install the disc brake caliper.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6277
Brake Caliper: Service and Repair Rear
Caliper Disassembly and Assembly
DISASSEMBLY AND ASSEMBLY
Caliper
Special Tools And Equipment
Special Tool(s)
Material
Material
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 or
piston is excessively scored or corroded, install a new rear disc brake caliper.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6278
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
1. Lubricate the following with brake fluid.
^ Cylinder bore.
^ Piston seal.
^ Caliper piston.
^ Dust boot.
2. Install the piston seal.
3. Using the special tools, install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
CAUTION: Insert the caliper piston squarely into the caliper bore.
Install the caliper piston. 1. Place the brake caliper in a vise. 2. Place the piston squarely against
the dust boot. 3. While applying shop air into the brake caliper, push the piston squarely into the
brake caliper bore.
5. Install the rear disc brake caliper.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6279
Brake Caliper Removal and Installation
Brake Caliper
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. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal injury.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Remove the bolt and disconnect the hose. ^
Remove and discard the copper washers.
3. Remove the brake pads.
4. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 6283
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)
Removal and Installation
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery.
2. Disconnect the anti-lock brake system (ABS) 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, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instruction may result in personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific
design and only authorized parts should be used when installing new inlet brake tubes.
NOTE: Plug each open port to prevent brake fluid from spilling.
Disconnect the hydraulic brake line nuts.
4. Remove the 3 bolts and the hydraulic control unit (HCU).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair > Page 6287
5. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder-Bypass Condition Test
Brake Master Cylinder: Testing and Inspection Brake Master Cylinder-Bypass Condition Test
Brake Master Cylinder-Bypass Condition Test
1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake
master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master
cylinder has an internal leak and must be rebuilt or installed new.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder-Bypass Condition Test > Page 6292
Brake Master Cylinder: Testing and Inspection Compensator Port Check
Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional
brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the
brake lines to the brake master cylinder to enter the brake master cylinder reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir.
Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal
and shows that the compensating ports are not plugged.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 6293
Brake Master Cylinder: Service and Repair
Brake Master Cylinder
Removal and Installation
All vehicles
1. Disconnect the battery.
Vehicles with cruise control
2. Disconnect the brake pressure switch electrical connector.
All vehicles
3. Disconnect the brake fluid level switch.
4. Loosen the brake line fittings and disconnect the brake lines.
^ Plug the master cylinder ports.
5. Remove the 2 nuts and the brake master cylinder. 6. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 and Installation
1. Remove the parking brake control.
2. Remove the front parking brake cable and conduit.
^ Pry the rubber seal from the front floor pan.
^ Compress the retainer and release the conduit from the bracket.
^ Remove the front cable and conduit from the cable union.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6299
Parking Brake Cable: Service and Repair Cable and Conduit - LH Rear
Removal and Installation
1. NOTE: The parking brake control is shown removed for clarity.
Make sure tension on the parking brake cables is fully released.
- While a helper pulls down on the front cable, insert a pin through the park brake control frame and
cam.
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 LH rear cable from the equalizer.
4. Remove the conduit from the bracket.
1 Compress the retainer.
2 Remove the conduit from the bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6300
5. Remove the LH rear cable.
1 Remove the LH rear cable from the retaining clip.
2 Disconnect the spring.
3 Disconnect the ABS sensor wire.
6. Remove the wireform bracket retaining screw.
7. Compress the retainer and release the conduit, then unclip the cable end from the lever. 8. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6301
Parking Brake Cable: Service and Repair Cable and Conduit - RH Rear
Removal and Installation
1. NOTE: The parking brake control is shown removed for clarity.
Make sure tension on the parking brake cables is fully released.
- While a helper pulls down on the front cable, insert a pin through the park brake control frame and
cam.
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 RH rear cable.
^ Remove the RH rear cable from the cable line.
^ Compress the cable clip and release the conduit from the equalizer.
4. Remove the RH rear cable from the retaining clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 6302
5. Remove the wireform bracket from the upper control arm.
6. Compress the retainer and release the conduit, then unclip the cable end from the lever. 7. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair
Parking Brake Control: Service and Repair
Removal and Installation
1. NOTE: The parking brake control is shown removed for clarity.
Make sure tension on the parking brake cables is fully released. ^
While a helper pulls down on the front cable, insert a pin through the park brake control frame and
cam.
2. Remove the door scuff plate.
3. Remove the screws and the finish panel.
^ Pull the weatherstrip back to release the edge of the panel.
4. Remove the release handle bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair > Page 6306
5. Remove the retainer and the cowl trim panel.
6. Disconnect the electrical connector at the solenoid.
7. Disconnect the electrical connector at the park detection switch.
8. Remove the park brake control bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair > Page 6307
9. Straighten the tab on the take-up spool.
10. Disconnect the conduit and remove the park brake control.
^ Compress the conduit retainer to disconnect it from the control.
11. Remove the release handle and cable assembly.
12. Remove the release solenoid.
^ Pry the mounting bracket apart slightly to release the solenoid.
13. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor >
Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor >
Component Information > Locations > Page 6311
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor >
Component Information > Locations > Page 6312
Parking Brake Release Motor: Service and Repair
Removal and Installation
1. Disconnect the electrical connector.
2. Remove the solenoid.
- Pry the mounting bracket apart slightly to release the solenoid.
- Disengage the solenoid from the release lever.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Service and Repair
Parking Brake Release Switch: Service and Repair
Removal and Installation
Column shift (Expedition only)
1. NOTE: The parking brake release switch is located on the steering column. It is serviced as an
assembly with the brake shift interlock.
Remove the brake shift interlock park brake release switch assembly.
Floor shift
2. Remove the floor shift selector lever. 3. Remove the screws, disconnect the electrical connector
and remove the switch.
All vehicles
4. To install, reverse the removal procedure.
^ Make sure the switch is correctly aligned with the extension on the shifter before installing the
screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Tools And Equipment
Special Tool(s)
Material
Material
Removal
1. NOTE: Verify that the parking brake control is fully released.
NOTE: This step will require the aid of an assistant.
Relieve the tension on the parking brake cable system. 1
Pull down on the front parking brake cable at the coupler.
2 Insert a 4 mm (5/32 inch) pin into the parking brake lever.
2. Remove the brake disc.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 6319
3. NOTE: The hub has been removed for clarity.
Remove the front parking brake shoe retaining clip and pin.
4. Remove the parking brake shoe adjuster.
- Using a suitable tool, spread the bottom of the parking brake shoes apart.
- Remove the parking brake shoe adjuster.
5. Remove the parking brake shoe adjuster spring.
6. Slide the front parking brake shoe up and out of the guide flange.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 6320
7. Remove the front parking brake shoe.
- Rotate the front parking brake shoe outward.
- Remove the parking brake shoe return spring.
8. Remove the rear parking brake shoe.
- Remove the retaining clip and pin.
- Remove the rear parking brake shoe.
9. Inspect the components for excessive wear or damage and install new parts as required.
Installation
1. NOTE: Before installation, lubricate the parking brake shoe contact points using silicone brake
caliper grease.
Install the rear parking brake shoe. Hold the rear parking brake shoe in position.
- Install the retaining pin and clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 6321
2. Install the front parking brake shoe.
- Install the parking brake shoe return spring to the rear parking brake shoe and to the front parking
brake shoe.
- Rotate the front parking brake shoe into the guide flange.
3. Slide the front parking brake shoe down into position on the flange.
4. Install the front parking brake shoe retaining pin and clip.
5. Install the parking brake shoe adjuster spring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 6322
6. Install the parking brake shoe adjuster.
^ Using a suitable tool, spread the bottom of the parking brake shoes apart.
- Install the parking brake shoe adjuster.
7. Using the special tool, measure the inside diameter of the drum portion of the rear brake disc.
- Record the measurement.
8. NOTE: Make sure that the parking brake shoes are correctly centered. Take the measurement at
the widest point across the center of the parking
brake shoes.
Using the special tool, measure the parking brake shoe diameter. Rotate the adjuster to set the parking brake shoe diameter to 5 mm (0.02 inch) less than the
recorded inside diameter of the drum portion of the rear brake disc.
9. Install the brake disc.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 6323
10. NOTE: This step will require the aid of an assistant.
Enable the parking brake cable system. 1
Pull down on the front parking brake cable at the coupler.
2 Remove the retaining pin from the parking brake lever.
11. Check the operation of the parking brake.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations > Page 6327
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 6332
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Customer Interest for Vacuum Brake Booster: > 05-26-21 > Dec > 05 > Brakes Unintended Brake Assist
Vacuum Brake Booster: Customer Interest Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 05-26-21 > Dec >
05 > Brakes - Unintended Brake Assist
Vacuum Brake Booster: All Technical Service Bulletins Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Page 6346
Vacuum Brake Booster: Specifications
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Page 6347
Vacuum Brake Booster: Description and Operation
Brake Booster
The power brake booster is a dual diaphragm, vacuum-assisted power brake booster. ^
reduces brake pedal pressure and travel distance.
^ is divided into separate vacuum and atmospheric pressure chambers by a diaphragm.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Hose and Check Valve
The power brake booster check valve: ^
closes when the engine is turned off.
^ in the closed position, traps engine vacuum in the power brake booster.
^ retains vacuum to provide several power-assisted brake applications with the engine off.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Page 6348
Vacuum Brake Booster: Testing and Inspection
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in
NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several
times to exhaust all
vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system
is operating, the brake pedal will tend to move
downward under constant foot pressure. If no motion is felt, the power brake booster system is not
functioning.
Brake Booster Operation Check
1. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be
available at the check valve end of the vacuum
booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold
vacuum is available to the power brake booster, connect the vacuum booster hose to the power
brake booster check valve and repeat Steps 2 and 3 of the Brake Booster check. If no downward
movement of the brake pedal is felt, install a new power brake booster.
2. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle
stand for 10 minutes. Then apply the brake pedal with
approximately 89 N (20 lb) of force. The brake pedal feel should be the same as that noted with the
engine operating. If the brake pedal feels hard (no power assist), install a new power brake booster
check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Page 6349
Vacuum Brake Booster: Service and Repair
Removal and Installation
1. Disconnect the battery negative cable.
2. Loosen the clamp and separate the air cleaner outlet tube and resonator from the air cleaner.
3. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
4. Lift the air cleaner assembly from the air cleaner tray.
5. Remove the screws and position aside the power steering reservoir.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Page 6350
6. Disconnect the brake fluid level switch and if equipped, the brake pressure switch.
7. NOTE: Support the master cylinder with a wire tie or mechanics wire.
Remove and discard the two nuts and position the master cylinder aside.
8. Remove the mounting bolts for the degas bottle and position aside.
9. If equipped, disconnect the wiring at the pedal travel sensor and solenoid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Technical Service Bulletins > Page 6351
10. Release the clamp and disconnect the hose.
11. Remove the pin, washer, bushing and switch, and disconnect the booster pushrod. 12. Remove
the nuts and the brake booster.
^ To access the retaining nuts, fold back the sound insulation.
13. NOTE: The booster pushrod must be installed with the pushrod offset pointing downward.
To install, reverse the removal procedure. ^
Use new nuts when installing the master cylinder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Brake Booster
The power brake booster is a dual diaphragm, vacuum-assisted power brake booster. ^
reduces brake pedal pressure and travel distance.
^ is divided into separate vacuum and atmospheric pressure chambers by a diaphragm.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Hose and Check Valve
The power brake booster check valve: ^
closes when the engine is turned off.
^ in the closed position, traps engine vacuum in the power brake booster.
^ retains vacuum to provide several power-assisted brake applications with the engine off.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Description and Operation > Page 6355
Vacuum Brake Booster Check Valve: Testing and Inspection
Check Valve
The function of the power brake booster check valve is to allow manifold vacuum to enter the
power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during
sustained full throttle operation. To test the function of the power brake booster check valve: ^
Start and run the engine for at least 10 seconds.
^ Operate the brake pedal to check for power assist.
^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power
brake booster check valve from the power brake booster.
^ There should be enough vacuum retained in the power brake booster for at least one more
power-assisted brake operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6360
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6361
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
NOTE: When installing a new module, it must be calibrated and configured (either by
download/upload or uploading the as-built data method).
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery.
2. Disconnect the ABS module electrical connector.
3. Remove the 3 bolts and the ABS module. 4. To install, reverse the removal procedure
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 6366
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6370
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 6375
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor > Page 6378
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Stability Control Sensor Cluster
Removal and Installation
NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the
yaw rate sensor, stability control sensor cluster.
1. Remove the front floor console.
2. Remove the 2 bolts and the stability control sensor cluster.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Service and Repair
Parking Brake Release Switch: Service and Repair
Removal and Installation
Column shift (Expedition only)
1. NOTE: The parking brake release switch is located on the steering column. It is serviced as an
assembly with the brake shift interlock.
Remove the brake shift interlock park brake release switch assembly.
Floor shift
2. Remove the floor shift selector lever. 3. Remove the screws, disconnect the electrical connector
and remove the switch.
All vehicles
4. To install, reverse the removal procedure.
^ Make sure the switch is correctly aligned with the extension on the shifter before installing the
screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations > Page 6388
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Removal and Installation
1. Disconnect the battery.
2. Remove the 2 bolts and the steering wheel rotation sensor.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
View 151-24 (Centre Console)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6395
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Right Front
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Right Front > Page 6400
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Right Front > Page 6401
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6404
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6405
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6406
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor-Front
Wheel Speed Sensor-Front
Removal and Installation
1. NOTE: If equipped, turn the air suspension switch to the OFF position.
With the vehicle in NEUTRAL, position it on a hoist
2. Disconnect the wheel speed sensor electrical connector.
3. Remove the bolt and the retainers.
4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front > Page 6409
5. Remove the brake disc.
6. Remove the bolt and the front wheel speed sensor. 7. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor-Front > Page 6410
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Removal and Installation
1. Remove the parking brake shoes.
2. Disconnect the wheel speed sensor wire from the retaining clips.
3. Remove the bolt and the rear wheel speed sensor. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 6414
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 6415
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Removal and Installation
NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the
yaw rate sensor, stability control sensor cluster.
1. Remove the front floor console.
2. Remove the 2 bolts and the stability control sensor cluster.
^ Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
6423
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
6424
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 6428
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6433
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB), in the engine compartment, RH
side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6434
Starter Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6435
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
Battery Cable: Service and Repair
BATTERY CABLES
Removal and Installation
1. Disconnect the battery.
2. Remove the negative battery cable ground bolt at the cowl panel.
3. Remove the nut and disconnect the positive battery cable at the positive battery terminal
junction. 4. For Navigator, release the clips and remove the engine cover.
5. Disconnect the electrical connector from the battery cable harness. 6. Raise the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 6440
7. Remove the 2 nuts and remove the battery cable harness from the 2 support bracket studs.
8. Remove the starter motor solenoid terminal cover.
9. Disconnect the starter motor connections.
1 Remove the nut and disconnect the starter motor battery ground cable.
2. Remove the nut and disconnect the starter solenoid cable. 3. Remove the nut and disconnect
the starter motor positive cable.
10. Remove the negative battery cable to frame bolt. 11. Remove the battery cable harness. 12. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349
Alternator: Customer Interest Charging System - DTC P0340/P0344/P0345/P0349
TSB 06-19-12
10/02/06
DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V
FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer
2007 Explorer Sport Trac
LINCOLN: 2005-2006 Navigator
MERCURY: 2006 Mountaineer
This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and
service parts updated.
ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005
and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT
vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or
P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a
4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning
diode or open phase connection in the generator.
ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the
generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for
performing a generator frequency test using the WDS oscilloscope function.
SERVICE PROCEDURE
NOTE
USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD
INDICATOR OF A FAULTY GENERATOR.
NOTE
ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE.
1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean
and secure.
2. Attach WDS battery cable clamps to battery/battery cables.
3. Turn on WDS.
4. Select the Toolbox Icon, (upper left of WDS screen).
5. Select Oscilloscope and then click OK.
6. Select Channel 1, Auto, Generator Ripple.
7. Select Calculations, Channel 1, Frequency.
8. Select Calculations again.
9. Push the RUN/STOP button. A waveform should display on the screen.
10. Start the vehicle and leave at idle (engine speed less than 800 RPM).
11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc).
12. Examine the frequency reading on WDS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6450
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6451
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6452
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6453
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349
Alternator: All Technical Service Bulletins Charging System - DTC P0340/P0344/P0345/P0349
TSB 06-19-12
10/02/06
DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V
FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer
2007 Explorer Sport Trac
LINCOLN: 2005-2006 Navigator
MERCURY: 2006 Mountaineer
This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and
service parts updated.
ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005
and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT
vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or
P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a
4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning
diode or open phase connection in the generator.
ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the
generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for
performing a generator frequency test using the WDS oscilloscope function.
SERVICE PROCEDURE
NOTE
USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD
INDICATOR OF A FAULTY GENERATOR.
NOTE
ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE.
1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean
and secure.
2. Attach WDS battery cable clamps to battery/battery cables.
3. Turn on WDS.
4. Select the Toolbox Icon, (upper left of WDS screen).
5. Select Oscilloscope and then click OK.
6. Select Channel 1, Auto, Generator Ripple.
7. Select Calculations, Channel 1, Frequency.
8. Select Calculations again.
9. Push the RUN/STOP button. A waveform should display on the screen.
10. Start the vehicle and leave at idle (engine speed less than 800 RPM).
11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc).
12. Examine the frequency reading on WDS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6459
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6460
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6461
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6462
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
ITEM.....................................................................................................................................................
...................................................SPECIFICATION
Voltage.................................................................................................................................................
........................................................................12 volts Generator
amps...............................................................................65/110 amp (max) @ 1,800-6,000
generator rpm, approximately 500-2,000 engine rpm
Generator
Load at 2,000 rpm................................................................................................................................
....................................................................65 amps No Load at 2,000 rpm........................................
.......................................................................................................................between 13.0 and 15.0
volts
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 6465
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Connector Views
Alternator: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6468
Alternator: Application and ID
ITEM.....................................................................................................................................................
...................................................SPECIFICATION
Generator.............................................................................................................................................
........................................................................110 amp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6469
Alternator: Description and Operation
GENERATOR
The charging system consists of the following components:
- battery
- generator with internal voltage regulator
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6470
Alternator: Service and Repair
GENERATOR
Removal and Installation
1. Disconnect the battery. 2. For Navigator, release the 2 retainers and remove the engine cover.
3. Position the air cleaner intake pipe aside. 4. Relieve the accessory drive belt tension and remove
the belt from the generator pulley.
5. Remove the 2 generator B+ cable locators from the generator bracket and the air cleaner stud
bolt.
6. Remove the bolts and the generator bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6471
7. CAUTION: This is a new style connector that has a press-to-release tab. Pulling on the tab could
result in damage to the connector or
harness.
Disconnect the generator electrical connections. 1
Remove the B+ cable nut and cable.
2 Disconnect the electrical connector.
8. Loosen the lower bolts and remove the generator. 9. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder - Non Functional
Ignition Lock: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder - Non Functional > Page 6477
Ignition Lock: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder - Non Functional > Page 6478
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
IGNITION LOCK CYLINDER - FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Remove the steering wheel.
2. Remove the screws and the steering column cover.
3. Disconnect the PATS transceiver electrical connector.
4. Remove the bolt and the PATS transceiver.
5. NOTE: The ignition lock cylinder must be in the accessory position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6484
Remove the ignition lock cylinder. 1
Depress the release pin.
2 Remove the lock cylinder. Verify the ignition switch lock operation.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6485
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
IGNITION LOCK CYLINDER - NON-FUNCTIONAL LOCK CYLINDER
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Remove the screws and the steering column cover.
4. Disconnect the PATS transceiver electrical connector.
5. Remove the bolt and the PATS transceiver. 6. Remove the ignition lock cylinder.
- Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
- Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
lock cylinder breaks loose.
- Remove and discard the ignition lock cylinder and drill shavings from the steering column.
7. Remove the bearing retainer. 8. Remove the steering column lock housing bearing and steering
column lock gear.
- Thoroughly clean all drill shavings from the steering column and inspect it for damage.
9. NOTE: Use a new ignition lock cylinder.
To install, reverse the removal procedure. Verify ignition switch lock cylinder operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 6489
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 6498
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 6504
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Motor: Customer Interest Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition >
Page 6513
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition
Starter Motor: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition > Page 6519
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications
Starter Motor: Electrical Specifications
ITEM.....................................................................................................................................................
...................................................SPECIFICATION
Starting System
Normal engine cranking speed.............................................................................................................
................................................................140-220 rpm Starter motor armature shaft maximum
runny............................................................................................................................................0.11
mm (0.004 in) Starter motor brush manufactured length......................................................................
..............................................................................16.8 mm (0.66 in.) Starter motor brush spring tens
ion.........................................................................................................................................................
...............18 N (65 oz) Starter motor commutator maximum runout.....................................................
..........................................................................................0.12 mm (0.005 in) Starter motor diameter
..............................................................................................................................................................
....................101.6 mm (4.0 in) Starter motor maximum load...............................................................
......................................................................................................................800 amps Starter motor
minimum stall torque (at 5
volts)........................................................................................................................................14.7
Nm (10.8 lb-ft) Starter motor no load current draw...............................................................................
..........................................................................................60-80 amps Starter motor normal load
current draw..........................................................................................................................................
....................130-220 amps Starter circuit maximum voltage drop (engine at normal operating
temperature).......................................................................................................0.5 volts
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications > Page 6522
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6523
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6524
Starter Motor: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6525
Starter Motor: Service and Repair
STARTER MOTOR
Removal and Installation
WARNING: When carrying out maintenance on the starting system be aware that the heavy gauge
leads are connected directly to the battery. Make sure the protective caps are in place when
maintenance is completed. Failure to follow these instructions may result in personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the starter terminal cover and remove the nut and the solenoid S terminal electrical
connection.
- To install, tighten to 6 Nm (53 lb-in).
4. Remove the nut and the solenoid B terminal electrical connection.
- To install, tighten to 12 Nm (9 lb-ft).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6526
5. Remove the nut and the starter battery ground cable from the stud.
- To install, tighten to 20 Nm (15 lb-ft).
6. Remove the two bolts, the stud bolt, and the starter motor.
- To install, tighten to 25 Nm (18 lb-ft).
7. To install, reverse the removal procedure.
- Install the starter fasteners finger tight.
- Tighten the upper bolt.
- Tighten the lower fasteners.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 6530
View 151-1 (Engine Compartment)
The fuel pump relay is located in the Central Junction Box (CJB), in the engine compartment, RH
side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 6531
Starter Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 6532
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6538
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6539
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6540
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6541
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6546
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box
Fuse: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6551
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6552
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6553
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6554
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6555
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6556
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6557
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Central Junction Box > Page 6558
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box
Fuse: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6561
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6562
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6563
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6564
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6565
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6566
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6567
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Central Junction Box > Page 6568
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box
Fuse Block: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6573
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6574
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6575
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6576
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6577
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6578
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6579
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Central Junction Box > Page 6580
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views
Fuse Block: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6583
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6584
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6585
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6586
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6587
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6588
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box
Fuse Block: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6591
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6592
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6593
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6594
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6595
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6596
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6597
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Central Junction Box > Page 6598
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection > Page 6602
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection > Page 6606
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314
Multiple Junction Connector: Diagrams C110-C314
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6611
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6612
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6613
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6614
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6615
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6616
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6617
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6618
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6619
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6620
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6621
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6622
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6623
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6624
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6625
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6626
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6627
Multiple Junction Connector: Diagrams C315-C2108
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6628
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6629
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6630
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6631
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6632
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6633
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6634
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6635
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6636
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6637
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6638
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6639
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6640
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C314 > Page 6641
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 6645
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 6646
Power Distribution Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 6647
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6652
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6656
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6660
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6661
Power Distribution Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6662
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box
Relay Box: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6667
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6668
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6669
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6670
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6671
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6672
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6673
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 6674
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6675
Relay Box: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6676
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6677
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6678
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6679
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6680
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6681
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6682
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Page 6683
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box
Relay Box: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6686
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6687
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6688
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6689
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6690
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6691
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6692
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 6693
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box
Relay Box: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6698
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6699
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6700
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6701
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6702
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6703
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6704
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Central Junction Box > Page 6705
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Page 6706
Relay Box: Diagrams
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Locations > Page 6707
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Locations > Page 6708
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Locations > Page 6709
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Locations > Page 6710
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Locations > Page 6711
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Locations > Page 6714
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box
Relay Box: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6717
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6718
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6719
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6720
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6721
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6722
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Central Junction Box > Page 6723
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Application and ID > Central Junction Box > Page 6724
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines
Wiring Harness: Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines
TSB 06-17-8
09/04/06
SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS
FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150,
Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750
LINCOLN:
2005-2007 Navigator 2006-2007 Mark LI
MERCURY: 2004-2007 Monterey 2005 Mariner
This article supersedes TSB 05-16-12 to update vehicle lines and model years.
ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the
service selection easier, and to reduce the number of harnesses required for service. Due to this
consolidation, service replacement harnesses may or may not look exactly like the production
harness being replaced. Service replacement harnesses may come equipped with additional
connectors that will not be used.
ACTION Should replacement of a production wire harness become necessary, determine whether
the harness is to be used in a WET or DRY environment, then refer to the appropriate Service
Procedure below.
SERVICE PROCEDURE
NOTE
IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY"
ALWAYS TREAT AS A "WET" ENVIRONMENT.
Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness:
Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a
rattle or becoming loose (Figure 1). If space allows,
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position the connectors so they point downward this will avoid the connector catching water in case
of a water leak.
Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness:
1. Cut each wire from the extra connector as close to the connector as possible (Figure 2).
2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3).
3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive
flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the
ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4).
4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness
in the area.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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Disclaimer
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Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6731
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)
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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.
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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 5 (2005))
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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.
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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 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6737
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6738
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 5 (2005))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
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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.
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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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6746
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Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6747
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6748
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6749
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6754
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction
Box
Fuse: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction
Box > Page 6759
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Box > Page 6760
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Box > Page 6761
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Box > Page 6762
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Box > Page 6763
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Box > Page 6764
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Box > Page 6765
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Box > Page 6766
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Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box
Fuse: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6769
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6770
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6771
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6772
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6773
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6774
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6775
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central
Junction Box > Page 6776
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box
Fuse Block: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6781
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6782
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6783
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6784
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6785
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6786
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6787
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central
Junction Box > Page 6788
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views
Fuse Block: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6791
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6792
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6793
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6794
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6795
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6796
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box
Fuse Block: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6799
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6800
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6801
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6802
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6803
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6804
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6805
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Central Junction Box > Page 6806
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Micro ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection > Page 6810
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Mini ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection > Page 6814
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314
Multiple Junction Connector: Diagrams C110-C314
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6819
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6820
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6821
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6822
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6823
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6824
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6825
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6826
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6827
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6828
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6829
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6830
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6831
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6832
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6833
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6834
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6835
Multiple Junction Connector: Diagrams C315-C2108
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6836
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6837
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6838
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6839
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6840
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6841
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6842
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6843
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6844
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6845
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6846
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6847
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6848
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C314 > Page 6849
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 6853
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 6854
Power Distribution Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 6855
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection > Page 6860
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection > Page 6864
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 6868
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 6869
Power Distribution Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 6870
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box
Relay Box: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6875
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6876
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6877
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6878
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6879
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6880
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6881
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Central Junction Box > Page 6882
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6883
Relay Box: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6884
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6885
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6886
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6887
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6888
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6889
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6890
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Page 6891
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box
Relay Box: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6894
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6895
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6896
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6897
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6898
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6899
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6900
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Central Junction Box > Page 6901
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box
Relay Box: Locations Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6906
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6907
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6908
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6909
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6910
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6911
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6912
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central
Junction Box > Page 6913
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6914
Relay Box: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6915
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6916
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6917
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6918
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6919
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6920
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6921
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6922
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box
Relay Box: Application and ID Central Junction Box
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6925
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6926
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6927
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6928
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6929
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6930
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6931
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Central Junction Box > Page 6932
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines
Wiring Harness: Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines
TSB 06-17-8
09/04/06
SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS
FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150,
Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750
LINCOLN:
2005-2007 Navigator 2006-2007 Mark LI
MERCURY: 2004-2007 Monterey 2005 Mariner
This article supersedes TSB 05-16-12 to update vehicle lines and model years.
ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the
service selection easier, and to reduce the number of harnesses required for service. Due to this
consolidation, service replacement harnesses may or may not look exactly like the production
harness being replaced. Service replacement harnesses may come equipped with additional
connectors that will not be used.
ACTION Should replacement of a production wire harness become necessary, determine whether
the harness is to be used in a WET or DRY environment, then refer to the appropriate Service
Procedure below.
SERVICE PROCEDURE
NOTE
IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY"
ALWAYS TREAT AS A "WET" ENVIRONMENT.
Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness:
Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a
rattle or becoming loose (Figure 1). If space allows,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6937
position the connectors so they point downward this will avoid the connector catching water in case
of a water leak.
Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness:
1. Cut each wire from the extra connector as close to the connector as possible (Figure 2).
2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3).
3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive
flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the
ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4).
4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness
in the area.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6938
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6939
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6940
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6941
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6942
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6943
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6944
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6945
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6946
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6947
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 5 (2005))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 6948
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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6954
Alignment: Specifications General Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6955
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6956
Alignment: Description and Operation
Wheel Alignment Angles
The front caster and camber are adjusted by removing the lower arm-to-frame mounting bolts and
installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the
use of the front wheel spindle tie-rod. The rear camber is adjusted by removing the upper
arm-to-wheel knuckle mounting bolt and installing an adjuster kit to allow the wheel knuckle to be
adjusted in the arm slot. The rear toe is adjusted by the use of the rear toe link.
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Toe
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6957
Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
Ride Height
NOTE: Air suspension vehicles must be at trim prior to measuring the vehicle ride height.
Front Ride Height Measurement
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6958
Rear Ride Height Measurement
Wheel Track
Dogtracking
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Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6959
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 Km/h (40 mph), and can begin or be amplified when the
tire contacts pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces or tire imbalance. This condition is observed by the driver as small rotational
oscillations of the steering wheel.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to
center after a turn or the steering correction is completed.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the
steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20 degrees of steering wheel turn). Efforts may be said to be flat on center. ^
Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear
teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the
effort from the self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment
Alignment: Service and Repair Front Toe Adjustment
Front Toe Adjustment
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the
caster, camber or toe.
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the straight forward position using a suitable holding device.
3. NOTE: Do not allow the steering gear bellows to twist while rotating the spindle tie-rod.
Remove the clamp(s).
4. Loosen the nut(s).
^ Clean and lubricate the nut(s) and spindle tie-rod threads.
5. Rotate the spindle tie-rod(s). 6. Start the engine and center the steering wheel.
^ Recheck the toe settings and adjust if necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment > Page 6962
7. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the
boot can occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Tighten the nut(s).
8. Install the clamp(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment > Page 6963
Alignment: Service and Repair Camber and Caster Adjustment - Front
Camber and Caster Adjustment Front
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the
caster, camber or toe.
1. NOTE: New lower arm-to-frame mounting bolts must be installed with cam bolt kits for forward
bushing; and for rearward bushing), to allow for
adjustment of the arm in the frame slot. The vehicle should be supported by the frame to ease
movement of the lower arm in the slot.
Remove the nuts and bolts. ^
Discard the nuts and bolts.
^ Install the cam bolt kit(s) and snug the nut(s).
2. To adjust the caster and camber, refer to the above chart.
^ Adjustments that require moving the front and the rear of the lower arm should be made equally.
3. While holding the cam bolt, tighten the nut(s). 4. Check and, if necessary, adjust the front toe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment > Page 6964
Alignment: Service and Repair Camber Adjustment - Rear
Camber Adjustment Rear
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear
camber or toe.
1. NOTE: Support the vehicle at the lower arm to ease the wheel knuckle movement in the upper
arm slot.
Measure and record the LH rear and RH rear camber angles.
2. Compare the recorded camber angles to the specifications. Refer to the Alignment
Specifications. 3. Determine desired camber adjustment (subtract the specified camber angle from
the measured camber angle). 4. Remove the rear wheel.
5. Mark a scribe line on the upper arm-to-wheel knuckle bolt head and upper arm.
6. Use the above table to determine the camber adjustment required.
^ Obtained by subtracting the specified camber angle from the measure camber angle.
7. Install a new upper arm-to-knuckle nut on the upper arm-to-knuckle bolt. 8. Position the upper
arm-to-knuckle bolt in the upper arm slot as required to adjust camber angle to the value obtained
in Step 6.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment > Page 6965
9. Tighten the upper arm-to-knuckle nut.
10. Install the wheel and tire assembly. 11. Using the alignment equipment, verify the camber
adjustment. 12. Check and if necessary, adjust the rear toe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment > Page 6966
Alignment: Service and Repair Rear Toe Adjustment
Rear Toe Adjustment
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear
toe.
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the straight forward position using a suitable holding device.
3. Loosen the nuts(s).
^ Clean and lubricate the nut(s) and rear toe link threads.
4. Rotate the spindle tie rod.
5. NOTE: Make sure the toe settings are not disturbed while tightening the nuts.
Tighten the nut(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Toe
Adjustment > Page 6967
Alignment: Service and Repair Ride Height Adjustments (Vehicle Dynamic Suspension)
Ride Height Adjustments
Special Tool(s)
Inflation and Deflation of the Air Suspension System
1. NOTE: Make sure that the air suspension switch is in the ON position.
NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this
procedure.
Turn the ignition switch to the ON position.
2. Connect the diagnostic tool to the Data Link Connector (DLC). 3. Select Air Suspension Control
Module under Active Command Mode. 4. Follow the diagnostic tool directions to lift or vent the front
or rear suspension.
Calibration
Ride Height Resetting
1. NOTE: Make sure that the air suspension switch is in the ON position.
NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this
procedure.
Turn the ignition to the OFF position. ^
Exit the vehicle, close all doors and allow the system to vent the vehicle down to kneel height
(approximately 45 seconds).
2. With the ignition in the ON position, shift the vehicle into DRIVE and then back to PARK.
^ Exit the vehicle, close all doors and allow the vehicle to pump to trim (approximately 45 seconds).
3. Measure the ride height. 4. Open the LF door. 5. Connect the diagnostic tool to the Data Link
Connector (DLC). 6. While outside of the vehicle, select the correct vehicle year, model and engine
type. 7. Select Vehicle Dynamic Module (VDM). 8. Using the active command mode, vent or lift the
vehicle to achieve the correct ride height. 9. Select the "Save Calibration Values (Store Ride
Height)" diagnostic tool command to calibrate the VDM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6973
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6974
Compressor/Pump Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6975
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Locations
Suspension Control Module: Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 6979
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 6980
Suspension Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 6981
Suspension Control Module: Service and Repair
Air Suspension Control Module
Removal and Installation
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery ground cable.
2. NOTE: The air suspension control module is mounted to the lower left side of the dash above
the parking brake control.
Disconnect the electrical connectors.
3. Pull back the dash padding to expose the module mounting nuts.
4. Remove the air suspension control module nuts.
5. 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 and pneumatic test be carried out.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Application and ID > Page 6986
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch > Page 6993
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 6997
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage
Loose
Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage
Loose > Page 7007
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height
Sensor Linkage Loose
Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor
Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height
Sensor Linkage Loose > Page 7013
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Page 7014
Ride Height Sensor: Service and Repair
Suspension Height Sensor
Removal and Installation
NOTE: Front shown, rear similar.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the LH
quarter trim panel. 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. Disconnect the sensor arm.
3. Remove and discard the nuts (front height sensor).
4. Remove and discard the bolts (rear height sensor).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins >
Page 7015
5. Disconnect the electrical connector.
6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle.
To install, reverse the removal procedure. ^
Calibrate the height sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7019
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 7023
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 7028
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 7029
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 7030
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Page 7031
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension to the OFF position. 2. Remove the wheel hub.
3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
4. Remove the bolt and position the brake hose aside.
5. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7036
6. Remove the nut and bolt.
^ Discard the nut.
7. Remove the three bolts.
8. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
9. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
NOTE: To separate the ball joint from the wheel knuckle, loosely install the nut and then tap on the
end of the stud.
Remove the nut and the wheel knuckle. ^
Discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7037
10. To install, reverse the removal procedure. 11. Check and, if necessary, align the front end.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Power Steering System Purging
Special Tool(s)
Material
CAUTION: If the air is not purged from the power steering system correctly, premature power
steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of
aerated fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The
power steering purge procedure must be carried out
prior to any component repair for which power steering noise complaints are accompanied by
evidence of aerated fluid.
Remove the power steering pump reservoir cap. Check the fluid.
2. Raise the front wheels off the floor.
3. Tightly insert the stopper of the vacuum pump into the reservoir. 4. Start the engine. 5. Install the
vacuum pump, apply vacuum, and maintain the maximum vacuum of 68 - 85 kPa (20 - 25 in-Hg).
6. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a
time. Damage to the power steering pump can
occur.
Cycle the steering wheel fully from stop to stop 10 times.
7. Stop the engine. 8. Release the vacuum and remove the vacuum pump.
9. CAUTION: Do not overfill the reservoir.
Fill the reservoir. ^
Use approved transmission fluid.
10. Start the engine. 11. Install the vacuum pump. Apply and maintain the maximum vacuum of 68
- 85 kPa (20 - 25 in-Hg).
12. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a
time. Damage to the power steering pump can
occur.
Cycle the steering wheel fully from stop to stop 10 times.
13. Stop the engine, release the vacuum, and remove the vacuum pump.
14. CAUTION: Do not overfill the reservoir.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 7042
Fill the reservoir as needed and install the reservoir cap.
15. Visually inspect the power steering system for leaks.
16. CAUTION: Do not overfill the reservoir.
Fill the reservoir as needed and visually inspect the power steering system for leaks.
17. Install the reservoir cap.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7047
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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications
Power Steering Fluid Capacity ............................................................................................................
....................................................2.7 pints (1.3 liters)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications > Page 7050
Power Steering Fluid: Fluid Type Specifications
Power Steering
........................................................................................................................MERCON
Multi-Purpose Transmission Fluid XT-2-QDX
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair
Power Steering Fluid Cooler: Service and Repair
Power Steering Fluid Cooler
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. With the vehicle in NEUTRAL, position the vehicle on a hoist.
3. Disconnect the clamps and remove the fluid cooler hoses.
4. Remove the 2 fluid cooler bolts and the fluid cooler. 5. To install, reverse the removal procedure.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Specifications
Power Steering Fluid Reservoir: Specifications
Fluid reservoir bolt (late build vehicles)
................................................................................................................................................ 10 Nm
(89 inch lbs.) Fluid reservoir bolts (early build vehicles)
.................................................................................................................................................. 11 Nm
(8 ft. lbs.) Fluid reservoir bracket-to-cylinder head bolt (early build vehicles)
.......................................................................................................... 80 Nm (59 ft. lbs.) Fluid
reservoir bracket-to-front engine cover stud (early build vehicles)
.................................................................................................. 25 Nm (18 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Specifications > Page 7057
Power Steering Fluid Reservoir: Service and Repair
Power Steering Fluid Reservoir
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
Early build vehicles
1. Remove the 3 fluid reservoir bolts.
2. Disconnect the clamp and remove the return hose.
^ Allow the fluid to drain into a suitable container.
3. Disconnect the clamp and remove the supply hose.
^ Remove the fluid reservoir.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Specifications > Page 7058
Late build vehicles
4. Disconnect the clamp and remove the return hose.
^ Allow the fluid to drain into a suitable container.
5. Disconnect the clamp and remove the supply hose.
6. Remove the fluid reservoir bolt and the fluid reservoir.
^ Lift the fluid reservoir from the front fender splash shield.
All vehicles
7. To install, reverse the removal procedure.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line
Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure
Line
Power Steering Pump to Steering Gear Pressure Line 4x4
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
All vehicles
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. Remove the engine cooling fan. 3. Remove the power steering pump pulley.
4. Disconnect the pressure line-to-pump fitting.
^ Discard the Teflon seal.
^ Allow the fluid to drain into a suitable container.
5. Remove the 2 bolts and the oil drip shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 7063
6. Remove the pressure line bracket-to-crossmember bolt.
7. Disconnect the pressure line from the frame rail retainers.
8. Remove the pressure line bracket-to-engine nut.
Expedition vehicles
9. Disconnect the pressure sensor electrical connector and the wiring harness retainer, if equipped.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 7064
10. Remove the steering line clamp plate bolt and the pressure line.
^ Discard the O-ring seal.
11. To install, reverse the removal procedure.
^ Using the special tool, install a new Teflon seal on the pressure line-to-pump fitting.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 7065
Power Steering Line/Hose: Service and Repair Power Steering Fluid Cooler to Power Steering
Fluid Reservoir Return Hose
Power Steering Fluid Cooler to Power Steering Fluid Reservoir Return Hose
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
All vehicles
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. With the vehicle in NEUTRAL, position the vehicle on a hoist.
Early build vehicles
3. Remove the 3 reservoir bolts.
4. Disconnect the clamp and remove the return line.
^ Allow the fluid to drain into a suitable container.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 7066
5. Disconnect the hose from the retainer clips.
Late build vehicles
6. Disconnect the clamp and remove the return line.
^ Allow the fluid to drain into a suitable container.
All vehicles
7. Disconnect the clamp and remove the return line.
8. Disconnect the hose from the frame rail retainer and remove the hose. 9. To install, reverse the
removal procedure.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 7067
Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose
Steering Gear to Fluid Cooler Return Hose
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
All vehicles
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
2. With the vehicle in NEUTRAL, position the vehicle on a hoist.
Navigator vehicles
3. Remove the pushpins and the deflector shield.
All vehicles
4. Disconnect the clamp and remove the return hose.
^ Allow the fluid to drain into a suitable container.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 7068
5. Remove the 2 bolts and the oil drip shield.
6. Remove the steering line clamp plate bolt.
7. Disconnect the frame rail retainers and remove the return line. 8. To install, reverse the removal
procedure.
^ Install a new O-ring seal.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Locations
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve
> Component Information > Locations > Page 7072
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications
Power Steering Pump: Specifications
Power Steering Pump
Flow (Navigator) ............................................................................. 11L ± 0.8L @ 345 kPa (3.0 gpm
± 0.2 gpm @ 50 psi), engine speed @ 2,500 rpm Flow (Expedition) ........... 11L ± 0.8L @ 345 kPa
(3.0 gpm ± 0.2 gpm @ 50 psi), engine speed @ 1,000 rpm, 9.5L ± 0.8L @ 345 kPa (2.5 gpm ± 0.2
gpm @ 50 psi), engine speed @ 2,800 rpm
Minimum capacity ..................................................................................................... 6.6L @ 5,171
kPa (1.6 gpm @ 750 psi), engine speed @ 500 rpm Relief pressure
........................................................................................................................................................
8,963 - 10,204 kPa (1,300 - 1,480 psi)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and Repair Power Steering Pump
Power Steering Pump
Special Tool(s)
Material
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. Remove the engine cooling fan. 2. Remove the power steering pump pulley.
3. Disconnect the clamp and remove the supply hose.
^ Allow the fluid to drain into a suitable container.
4. Remove the pressure line bracket-to-engine nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7078
5. Disconnect the pressure line-to-pump fitting.
^ Discard the Teflon seal.
6. Remove the 3 pump bolts.
^ Disconnect the harness retainer and remove the power steering pump.
7. To install, reverse the removal procedure.
^ Using the special tool, install a new Teflon seal on the pressure line-to-pump fitting.
^ Fill the power steering system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7079
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Power Steering Pump Pulley
Special Tool(s)
Removal
1. Rotate the tensioner clockwise and remove the engine accessory drive belt from the power
steering pump pulley.
2. Disconnect the mass air flow (MAF) sensor electrical connector.
3. Disconnect the electrical connector and loosen the air cleaner outlet canister and pipe clamps.
^ Remove the air cleaner outlet canister and pipe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7080
4. Using the special tool, remove the power steering pump pulley.
Installation
1. CAUTION: If the pulley has been removed and installed twice, install a new power steering
pump pulley.
Using the special tool, install the power steering pump pulley. ^
Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a
new pulley. If there is 1 paint mark or none at all, use a paint pencil to mark the web area of the
pulley near the hub.
2. Install the air cleaner outlet canister and pipe.
^ Connect the electrical connector and tighten the air cleaner outlet canister and pipe clamps.
3. Connect the MAF sensor electrical connector. 4. Rotate the tensioner clockwise and install the
engine accessory drive belt on the power steering pump pulley.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page
7086
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission electronic pressure control (EPC) pressure during increased
engine load, for example during parking maneuvers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 7090
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 7094
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7100
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7101
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7102
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7103
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7104
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7105
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7106
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7107
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7108
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7109
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7110
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7111
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7112
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering Wheel
Nibble at 65MPH
Steering Gear: Customer Interest Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH
TSB 05-7-2
04/18/05
STEERING WHEEL NIBBLE AT 65 MPH (105 KM/H) OR HIGHER
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 03-12-07 to add model years and update the Service Procedure.
ISSUE Some Expedition/Navigator may exhibit a steering wheel nibble (side-to-side or rotational
oscillation) at 65 MPH (105 km/h) or higher.
ACTION Refer to the Diagnostic Overview. Based on the customer's description of the concern,
find the appropriate Operating Condition and Probable Cause. If the vehicle concern and operating
conditions match those on the Diagnostic Overview, follow the TSB Service Procedure to repair.
NOTE
IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS
WHEN THE VIBRATION OR NIBBLE IS OCCURRING TO PROPERLY DIAGNOSE AND REPAIR
THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC
VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO
CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ).
SERVICE INFORMATION
NOTE
NIBBLE CANNOT BE ELIMINATED WITHOUT PROPER TIRE AND WHEEL BALANCE.
1. Drive the vehicle at highway speeds for at least 20 miles (33 km) to eliminate the flat spotting.
Install an EVA or Vetronix vibration analyzer and have an assistant monitor and record the reading
near the end of the 20 miles (33 km) drive and while at the peak of the vibration.
a. If the vibration goes away during the 20 mile (33 km) drive, the concern is due to temporary tire
flat spotting which is a normal tire condition. Do not continue with this TSB.
b. If the vibration remains, proceed to Step 2 for 4x4 vehicles, or to Step 3 for 4x2 vehicles.
NOTE
THE VEHICLE MUST BE DRIVEN TO REMOVE TIRE FLAT SPOTS, THE TIRE BALANCE AND
ROAD FORCE MEASUREMENTS MAY BE INACCURATE OTHERWISE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering Wheel
Nibble at 65MPH > Page 7121
2. Check the Integrated Wheel End (IWE) on 4x4 units. Raise the front of the vehicle (wheels off
the ground), engine running, and vehicle in 2WD mode. The front half shafts should not turn when
wheels are rotated by hand.
a. If the IWE is functioning correctly, proceed to Step 3.
b. If not, refer to Workshop Manual Section 308-07 and repair IWE first, then proceed to Step 3.
NOTE
THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE
MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK
RUN OUT WHEN ABSOLUTELY NECESSARY. VISIT WEBSITE (WWW.G5P9700.COM) TO
LOCATE THE NEAREST FACILITY THAT HAS THIS TYPE OF EQUIPMENT.
3. If road force measurement equipment (Hunter GSP 9700, 9712, or equivalent) is available,
proceed to Step 4. If not, balance the tires with a standard balancer and use a dial indicator to
locate and mark the high point of each tire's centerline radial runout. This will be used for the R1H
reading in the following steps. After marking the tires, proceed to Step 7.
NOTE
SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL
RESIDUALS TO BE DISPLAYED.
4. Perform the road force measurement immediately after driving the vehicle. Remove the wheel
cover and wheel assembly. Measure the road force variation of all four tires. Measure and mark the
tire HIGH road force variation point (R1H) on all four tires prior to dismounting them from the road
force measurement equipment. Balance as required to 0.35 oz (10g) or less of imbalance (check
both two-plane and static). If any wheel assembly measures more than 25 lbs R1H, then proceed
to Step 5. If less than 25 lbs R1H, proceed to Step 6.
5. Using the road force measurement equipment, determine the low spot of the wheel run out.
Match high point force variation on the tire with the low spot of wheel run out. If the wheel assembly
is now acceptable, continue with rebalance. If not, replace the tire and recheck.
NOTE
THE SPARE TIRE SHOULD NOT BE USED AS A REPLACEMENT TIRE.
6. Install the lowest R1H level tires on the front of the vehicle.
7. Position all tire/wheel assemblies on the hubs with the high R1H point, or high tire centerline
radial run out, at the 12:00 position (Figure 2).
8. Install the lug nuts and torque to 150 lb-ft (200 N.m).
9. Using a flat feeler gauge, check the wheel hub-to-bore clearance to verify the largest gap is as
close to the 6:00 position as possible (Figure 2). If the largest gap is not located near the 6:00
position, remove the lug nuts and tire/wheel assembly, rotate the hub to a new position, and
reinstall the tire/wheel assembly again following Steps 7 and 8. Check again for the optimum 6:00
gap location.
10. Road test vehicle to verify vehicle is corrected. If not corrected, proceed to Step 11.
11. Replace the steering gear per the following vehicle and build date information.
NOTE
DO NOT REPLACE THE STEERING GEAR UNLESS NIBBLE CANNOT BE RESOLVED WITH
TIRE/WHEEL BALANCE.
^ Expedition built from 3/17/2002-7/15/2002:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering Wheel
Nibble at 65MPH > Page 7122
2L1Z-3504-KB
^ Expedition built from 7/15/2002-5/20/2004: 4L1Z-3504-AA
^ Expedition built after 5/20/2004: Do not replace the steering gear. These vehicles already contain
the latest level.
^ Navigator built from 3/18/2002-6/27/2003: 4L7Z-3504-AA
^ Navigator built after 6/27/2003: Do not replace the steering gear. These vehicles already contain
the latest level.
NOTE
WHEN REPLACING NAVIGATOR STEERING GEAR, ALSO REFER TO TSB 03-11-05 FOR
INFORMATION ON REPROGRAMMING THE IVD MODULE.
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: 03-11-05
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3504 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering Wheel
Nibble at 65MPH > Page 7123
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering
Wheel Nibble at 65MPH
Steering Gear: All Technical Service Bulletins Steering/Tires/Wheels - Steering Wheel Nibble at
65MPH
TSB 05-7-2
04/18/05
STEERING WHEEL NIBBLE AT 65 MPH (105 KM/H) OR HIGHER
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 03-12-07 to add model years and update the Service Procedure.
ISSUE Some Expedition/Navigator may exhibit a steering wheel nibble (side-to-side or rotational
oscillation) at 65 MPH (105 km/h) or higher.
ACTION Refer to the Diagnostic Overview. Based on the customer's description of the concern,
find the appropriate Operating Condition and Probable Cause. If the vehicle concern and operating
conditions match those on the Diagnostic Overview, follow the TSB Service Procedure to repair.
NOTE
IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS
WHEN THE VIBRATION OR NIBBLE IS OCCURRING TO PROPERLY DIAGNOSE AND REPAIR
THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC
VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO
CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ).
SERVICE INFORMATION
NOTE
NIBBLE CANNOT BE ELIMINATED WITHOUT PROPER TIRE AND WHEEL BALANCE.
1. Drive the vehicle at highway speeds for at least 20 miles (33 km) to eliminate the flat spotting.
Install an EVA or Vetronix vibration analyzer and have an assistant monitor and record the reading
near the end of the 20 miles (33 km) drive and while at the peak of the vibration.
a. If the vibration goes away during the 20 mile (33 km) drive, the concern is due to temporary tire
flat spotting which is a normal tire condition. Do not continue with this TSB.
b. If the vibration remains, proceed to Step 2 for 4x4 vehicles, or to Step 3 for 4x2 vehicles.
NOTE
THE VEHICLE MUST BE DRIVEN TO REMOVE TIRE FLAT SPOTS, THE TIRE BALANCE AND
ROAD FORCE MEASUREMENTS MAY BE INACCURATE OTHERWISE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering
Wheel Nibble at 65MPH > Page 7129
2. Check the Integrated Wheel End (IWE) on 4x4 units. Raise the front of the vehicle (wheels off
the ground), engine running, and vehicle in 2WD mode. The front half shafts should not turn when
wheels are rotated by hand.
a. If the IWE is functioning correctly, proceed to Step 3.
b. If not, refer to Workshop Manual Section 308-07 and repair IWE first, then proceed to Step 3.
NOTE
THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE
MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK
RUN OUT WHEN ABSOLUTELY NECESSARY. VISIT WEBSITE (WWW.G5P9700.COM) TO
LOCATE THE NEAREST FACILITY THAT HAS THIS TYPE OF EQUIPMENT.
3. If road force measurement equipment (Hunter GSP 9700, 9712, or equivalent) is available,
proceed to Step 4. If not, balance the tires with a standard balancer and use a dial indicator to
locate and mark the high point of each tire's centerline radial runout. This will be used for the R1H
reading in the following steps. After marking the tires, proceed to Step 7.
NOTE
SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL
RESIDUALS TO BE DISPLAYED.
4. Perform the road force measurement immediately after driving the vehicle. Remove the wheel
cover and wheel assembly. Measure the road force variation of all four tires. Measure and mark the
tire HIGH road force variation point (R1H) on all four tires prior to dismounting them from the road
force measurement equipment. Balance as required to 0.35 oz (10g) or less of imbalance (check
both two-plane and static). If any wheel assembly measures more than 25 lbs R1H, then proceed
to Step 5. If less than 25 lbs R1H, proceed to Step 6.
5. Using the road force measurement equipment, determine the low spot of the wheel run out.
Match high point force variation on the tire with the low spot of wheel run out. If the wheel assembly
is now acceptable, continue with rebalance. If not, replace the tire and recheck.
NOTE
THE SPARE TIRE SHOULD NOT BE USED AS A REPLACEMENT TIRE.
6. Install the lowest R1H level tires on the front of the vehicle.
7. Position all tire/wheel assemblies on the hubs with the high R1H point, or high tire centerline
radial run out, at the 12:00 position (Figure 2).
8. Install the lug nuts and torque to 150 lb-ft (200 N.m).
9. Using a flat feeler gauge, check the wheel hub-to-bore clearance to verify the largest gap is as
close to the 6:00 position as possible (Figure 2). If the largest gap is not located near the 6:00
position, remove the lug nuts and tire/wheel assembly, rotate the hub to a new position, and
reinstall the tire/wheel assembly again following Steps 7 and 8. Check again for the optimum 6:00
gap location.
10. Road test vehicle to verify vehicle is corrected. If not corrected, proceed to Step 11.
11. Replace the steering gear per the following vehicle and build date information.
NOTE
DO NOT REPLACE THE STEERING GEAR UNLESS NIBBLE CANNOT BE RESOLVED WITH
TIRE/WHEEL BALANCE.
^ Expedition built from 3/17/2002-7/15/2002:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering
Wheel Nibble at 65MPH > Page 7130
2L1Z-3504-KB
^ Expedition built from 7/15/2002-5/20/2004: 4L1Z-3504-AA
^ Expedition built after 5/20/2004: Do not replace the steering gear. These vehicles already contain
the latest level.
^ Navigator built from 3/18/2002-6/27/2003: 4L7Z-3504-AA
^ Navigator built after 6/27/2003: Do not replace the steering gear. These vehicles already contain
the latest level.
NOTE
WHEN REPLACING NAVIGATOR STEERING GEAR, ALSO REFER TO TSB 03-11-05 FOR
INFORMATION ON REPROGRAMMING THE IVD MODULE.
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: 03-11-05
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3504 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 05-7-2 > Apr > 05 > Steering/Tires/Wheels - Steering
Wheel Nibble at 65MPH > Page 7131
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 7132
Steering Gear: Specifications
Power Steering Gear
Type .....................................................................................................................................................
..................................................... Rack and Pinion Ratio Navigator ...................................................
.........................................................................................................................................................
17:1 Ratio Expedition ..........................................................................................................................
................................................................................ 20:1 Static steering wheel turning effort
Navigator .............................................................................................................................................
........................................ 4.0 Nm (35 inch lbs.) Expedition .................................................................
.................................................................................................................. 5.0 Nm (44 inch lbs.)
Turning effort
Navigator .............................................................................................................................................
............................................ 2.14 kg (4.7 lbs.) Expedition ...................................................................
....................................................................................................................... 2.68 kg (5.9 lbs.)
Turns of steering wheel (lock to lock linkage disconnected)
......................................................................................................................................... 3.3 Steering
gear bracket-to-gear bolts and nuts (M14)
........................................................................................................................... 150 Nm (111 ft. lbs.)
Steering gear bracket-to-crossmember bolts and nuts (M12)
.............................................................................................................. 103 Nm (76 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 7133
Steering Gear: Service and Repair
Steering Gear 4x4
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
All vehicles
1. Place the front wheels in the straight-ahead position and the ignition switch in the OFF position.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located near the jack
storage area in the rear of the passenger compartment. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations. Failure to follow these instructions may result in personal injury.
Turn the air suspension switch to the OFF position, if equipped.
3. Remove the engine cooling fan.
4. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the
nut.
Remove the 2 nuts and disconnect the tie-rod ends from the wheel knuckles.
5. Remove the 2 bolts and the oil drip shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 7134
6. Disconnect the lines from the frame rail retainers.
7. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or
damage to the clockspring can occur. If there is
evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered.
Remove the intermediate shaft-to-gear pinch bolt and disconnect the intermediate shaft from the
gear.
8. Remove the steering line clamp plate bolt and disconnect the power steering lines.
^ Position the lines aside.
^ Discard the O-ring seals.
Navigator vehicles
9. Disconnect the electrical connector.
^ Rotate the actuator until the connector housing is facing the steering gear input shaft.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 7135
10. Remove the LH lower arm-to-frame nut and bolt.
^ Discard the nut.
11. Insert a block of wood between the LH lower arm and the frame.
All vehicles
12. Remove the 2 steering gear bracket-to-crossmember nuts and bolts.
^ Discard the nuts.
13. CAUTION: Make sure the steering lines are clear from the removal path of the gear or damage
to the lines can result.
Remove the 2 steering gear bracket-to-gear nuts, bolts, and brackets. ^
Discard the nuts.
14. Remove the steering gear from the LH side of the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 7136
15. CAUTION: Make sure that the wheel end vacuum line is clear of the steering gear mounting
fasteners before tightening the bolts or damage to
the line can result.
CAUTION: Make sure to tighten the bracket-to-steering gear bolts (M14) before tightening the
bracket-to-crossmember bolts (M12) or damage to the steering gear can result.
To install, reverse the removal procedure. ^
Install a new high pressure line O-ring seal and a new return line O-ring seal.
^ Fill and leak check the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical
Service Bulletins > Customer Interest for Steering Shaft: > 04-26-23 > Dec > 04 > Steering - Steering Column
Creak/Pop/Tick Noise
Steering Shaft: Customer Interest Steering - Steering Column Creak/Pop/Tick Noise
TSB 04-26-23
12/31/04
CLUNK, POP, CREAK OR TICK NOISE FROM STEERING COLUMN
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 04-16-14 to update the Service Procedure and affected model years.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 10/18/2004 may exhibit a clunk,
pop, creak, or tick noise coming from the steering column. The noise may occur during
acceleration, deceleration and/or while going over bumps, and is most noticeable after the vehicle
is warmed up. The tick noise may occur when rapidly and repeatedly turning the steering wheel to
the left or right.
ACTION For a clunk, pop or creak condition, it may be necessary to replace the lower intermediate
steering shaft. For a tick condition, inspect the upper-to-lower intermediate shaft union. Refer to the
correct Service Procedure based on symptom.
SERVICE PROCEDURE - Clunk, Pop Or Creak
NOTE
DO NOT ATTEMPT TO ADD GREASE TO THE INTERMEDIATE SHAFT TO RESOLVE THE
CONDITION.
NOTE
BE SURE THE VEHICLE IS AT FULL OPERATING TEMPERATURE DURING VERIFICATION.
1. Road test the vehicle to verify the condition.
2. If condition is verified, replace the lower intermediate steering shaft following the service
procedure in Workshop Manual Section 211-04. Torque the upper-to-lower intermediate shaft bolt
to 40 lb-ft (55 N.m).
NOTE
CHECK BUILD DATE CODES ON THE REPLACEMENT SHAFT PRIOR TO INSTALLATION.
ONLY INSTALL PARTS BUILT AFTER DATE CODE 0410080X (OCTOBER 8, 2004). THE LAST
TWO DIGITS OF THE DATE CODE (0X) INDICATE THE SHIFT IN WHICH THE PARTS WERE
BUILT (X CAN EQUAL 1, 2, OR 3).
SERVICE PROCEDURE - Tick
1. Turn steering wheel rapidly and repeatedly to the left or right while parked to verify the condition.
2. If the condition is verified, inspect the upper-to-lower intermediate shaft union and re-torque the
bolt to 40 lb-ft (55 N.m).
3. If the noise is still present, follow normal diagnostics.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical
Service Bulletins > Customer Interest for Steering Shaft: > 04-26-23 > Dec > 04 > Steering - Steering Column
Creak/Pop/Tick Noise > Page 7145
Labor Operation Claiming Chart
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3B676 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 04-26-23 > Dec > 04 > Steering - Steering Column
Creak/Pop/Tick Noise
Steering Shaft: All Technical Service Bulletins Steering - Steering Column Creak/Pop/Tick Noise
TSB 04-26-23
12/31/04
CLUNK, POP, CREAK OR TICK NOISE FROM STEERING COLUMN
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 04-16-14 to update the Service Procedure and affected model years.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 10/18/2004 may exhibit a clunk,
pop, creak, or tick noise coming from the steering column. The noise may occur during
acceleration, deceleration and/or while going over bumps, and is most noticeable after the vehicle
is warmed up. The tick noise may occur when rapidly and repeatedly turning the steering wheel to
the left or right.
ACTION For a clunk, pop or creak condition, it may be necessary to replace the lower intermediate
steering shaft. For a tick condition, inspect the upper-to-lower intermediate shaft union. Refer to the
correct Service Procedure based on symptom.
SERVICE PROCEDURE - Clunk, Pop Or Creak
NOTE
DO NOT ATTEMPT TO ADD GREASE TO THE INTERMEDIATE SHAFT TO RESOLVE THE
CONDITION.
NOTE
BE SURE THE VEHICLE IS AT FULL OPERATING TEMPERATURE DURING VERIFICATION.
1. Road test the vehicle to verify the condition.
2. If condition is verified, replace the lower intermediate steering shaft following the service
procedure in Workshop Manual Section 211-04. Torque the upper-to-lower intermediate shaft bolt
to 40 lb-ft (55 N.m).
NOTE
CHECK BUILD DATE CODES ON THE REPLACEMENT SHAFT PRIOR TO INSTALLATION.
ONLY INSTALL PARTS BUILT AFTER DATE CODE 0410080X (OCTOBER 8, 2004). THE LAST
TWO DIGITS OF THE DATE CODE (0X) INDICATE THE SHIFT IN WHICH THE PARTS WERE
BUILT (X CAN EQUAL 1, 2, OR 3).
SERVICE PROCEDURE - Tick
1. Turn steering wheel rapidly and repeatedly to the left or right while parked to verify the condition.
2. If the condition is verified, inspect the upper-to-lower intermediate shaft union and re-torque the
bolt to 40 lb-ft (55 N.m).
3. If the noise is still present, follow normal diagnostics.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 04-26-23 > Dec > 04 > Steering - Steering Column
Creak/Pop/Tick Noise > Page 7151
Labor Operation Claiming Chart
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3B676 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical
Service Bulletins > Page 7152
Steering Shaft: Service and Repair
Steering Column Shaft
Removal and Installation
All vehicles
1. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is
disconnected or damage to the clockspring can result.
If there is evidence that the shaft has rotated, the clockspring must be removed and recentered.
Remove the bolt and disconnect the intermediate shaft from the steering column. ^
Discard the bolt.
2. Remove the bolt and disconnect the upper intermediate shaft from the lower intermediate shaft.
^ Discard the bolt.
3. Remove the bolts, dash seal and the upper intermediate shaft.
Navigator 4x4 vehicles
4. Remove the cooling fan and shroud.
All vehicles except Navigator 4x4
5. Raise and support the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical
Service Bulletins > Page 7153
6. If equipped, remove the skid plate.
All vehicles
7. Remove the bolt and the lower intermediate shaft.
^ Discard the bolt.
8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 7162
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 5 (2005))
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 5 (2005))
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 7168
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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and
Repair > Steering Wheel
Steering Wheel: Service and Repair Steering Wheel
Steering Wheel
Special Tool(s)
Removal and Installation
1. Turn the steering wheel to the straight-ahead position and turn the ignition switch to the OFF
position. 2. Remove the driver air bag module.
3. Loosen the steering wheel bolt.
4. Disconnect the electrical connector.
5. 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 from the steering column
shaft.
6. Remove and discard the original steering wheel bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and
Repair > Steering Wheel > Page 7171
7. Remove the steering wheel while routing the wires from the clockspring through the steering
wheel. 8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and
Repair > Steering Wheel > Page 7172
Steering Wheel: Service and Repair Steering Wheel Audio Controls
STEERING WHEEL AUDIO CONTROLS
Removal and Installation
All Vehicles 1. Remove the driver air bag module.
Expedition
2. Remove the 2 screws and the steering wheel audio controls switch.
- Disconnect the electrical connector.
Navigator
3. Remove the 4 steering wheel audio controls switch screws. 4. Remove the bolts and springs,
and position the horn switch plate aside.
5. NOTE: Note the routing of the steering wheel audio controls harness on the module plate for
installation of the new steering wheel audio
controls.
Disconnect the steering wheel audio controls harness from the clips, and remove the horn switch
plate.
All Vehicles 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair
Tie Rod: Service and Repair
Inner Tie Rod
Special Tool(s)
Material
Removal
CAUTION: The boots and clamps are designed to provide an airtight seal and protect the internal
components of the steering gear. If the seal is not airtight the vacuum generated during turning will
draw water and contamination into the gear causing premature damage.
CAUTION: Zip ties do not produce an airtight seal and must not be used.
CAUTION: The inner ball joint grease is not compatible with water and contamination trapped in
the grease will degrade the life of the joint.
CAUTION: If present, the orientation of the vent tube must be noted so the boots and vent tubes
can be installed in the correct location.
1. With the vehicle in NEUTRAL, position the vehicle on a hoist.
2. Loosen the tie-rod end jam nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 7176
3. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the
tie-rod end nut.
Remove the nut and disconnect the tie-rod end from the wheel knuckle.
4. NOTE: Note the number of times the tie-rod ends turn for assembly reference.
Remove the tie-rod end.
5. Remove the tie-rod end jam nut.
6. NOTE: If repairing the RH side, it will be necessary to pull back the LH inner tie rod bellows to
hold the steering gear.
Remove the inner and outer bellows clamps.
7. Remove the inner tie-rod bellows.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 7177
8. CAUTION: Place the steering gear at the center position. Use a 11/16 in. crowfoot on the flat of
the rack gear to resist rotation and to prevent
damage during removal and installation of the inner tie-rod.
NOTE: An assistant may be needed for removal of the RH inner tie-rod.
Using the (A) special tool, remove the (B) inner tie-rod.
9. CAUTION: Thoroughly remove any abrasive material. This material is extremely harmful to the
steering gear.
Thoroughly clean and inspect all the parts to be reused. Replace the parts as necessary.
Installation
1. Lubricate the inner tie-rod groove with steering gear grease where the inner tie-rod bellows is
clamped.
^ Check that the inner tie-rod bellows is positioned correctly over the steering gear housing bead at
the large inside diameter (ID) and is in the inner tie-rod groove at the small ID.
^ Check that the inner tie-rod bellows is not twisted and the breather tube is securely inserted into
the breather nipple at both inner tie-rod bellows.
2. To install, reverse the removal procedure. 3. Check the wheel alignment. Adjust as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7183
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7184
Ball Joint: Specifications Torque Specifications
Upper ball joint nut ...............................................................................................................................
................................................. 150 Nm (111 ft. lbs.) Lower ball joint nut ...........................................
.................................................................................................................................... 200 Nm (148 ft.
lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7185
Ball Joint: Specifications General Specifications
Ball Joint End Play
Lower ball joint (front) maximum vertical
........................................................................................................................................ 0.8 mm
(0.032 inch) Upper ball joint maximum vertical
..................................................................................................................................................... 0.2
mm (0.008 inch)
Wear Limit
Any movement at or exceeding the specification indicates a worn or damaged lower ball joint.
Install a new ball joint as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection
Ball Joint: Testing and Inspection Ball Joint Inspection
Ball Joint Inspection
1. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the
front wheel bearings.
3. Position a safety stand beneath the front suspension lower arm to be tested.
4. While an assistant pries upward on the bottom of the tire, measure the relative movement
between the lower spindle arm and the front suspension
lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged
lower ball joint. Install a new ball joint as necessary.
5. While an assistant pries upward on the bottom of the tire, measure the relative movement
between the upper spindle arm and the front suspension
upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper
ball joint. Install a new upper ball joint as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 7188
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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 7189
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7190
Ball Joint: Service and Repair
Ball Joint - Lower
Special Tool(s)
Special Tool(s)
Material
Material
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7191
Removal
1. Remove the wheel knuckle. 2. Remove and discard the lower ball joint snap ring. 3. Using the
special tools, remove the lower ball joint.
Installation
1. Using a clean shop towel and the specified surface cleaner, clean the lower arm ball joint bore
and inspect for cracks or damage before installing a
new ball joint. If there is evidence of cracks or damage, a new lower arm must be installed.
2. CAUTION: Use care to prevent adhesive from contacting the ball joint boot or damage to the
boot may occur, causing premature ball joint
failure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7192
NOTE: To allow the adhesive to fully cure, the vehicle must not be driven on the road for at least
one hour after the installation of a new ball joint .
Apply an even coat of adhesive (supplied with kit) to the lower arm ball joint bore and the ball joint.
3. CAUTION: Do not damage the lower ball joint boot when installing the special tool or premature
failure of the ball joint may occur.
NOTE: Make sure the ball joint snap ring is fully seated.
Using the special tools, install the lower ball joint.
Install the ball joint snap ring.
4. Using a clean shop towel and the specified surface cleaner, wipe any excess adhesive from the
ball joint and lower arm.
5. Install the wheel knuckle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front
Control Arm: Service and Repair Front
Lower Arm
Lower Arm
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel knuckle.
3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
4. Remove the nut and bolt.
^ Discard the nut.
5. Remove the nut and bolt.
^ Discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7197
6. Remove the nut, bolt and the lower arm.
^ Discard the nut.
7. NOTE: Assemble the lower arm pivot nuts and bolts. Do not tighten until the installation
procedure is complete and the weight of the vehicle is
resting on the wheel and tire assemblies.
To install, reverse the removal procedure.
8. Check and, if necessary, align the front end.
Upper Arm
For Service and Repair information refer to 4x2 See: Upper Arm
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7198
Control Arm: Service and Repair Rear
Lower
Lower Arm
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
4. Remove the bolt and flag nut.
^ Discard the flag nut.
5. Remove the nut and bolt.
^ Discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7199
6. Remove the nut and bolt.
^ Discard the nut.
7. Remove the bolt, flag nut and the lower arm.
^ Discard the flag nut.
8. If necessary, using a suitable press and adapters, remove the lower ball joint.
9. NOTE: Snug the lower arm-to-frame pivot nuts and bolts. Do not tighten to specification until
installation procedure is complete and the vehicle
is at curb ride height.
To install, reverse the removal procedure. ^
Check and, if necessary, adjust the rear alignment.
Upper
Upper Arm
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped turn the air suspension switch to the OFF position 2. Remove the wheel and tire
assembly.
3. Remove the nut and bolt.
^ Discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7200
4. Remove the nut and bolt.
^ Discard the nut.
5. Remove the nut, bolt and the upper arm.
^ Discard the nut.
6. To install, reverse the removal procedure. 7. Check and, if necessary, adjust the rear alignment.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 7206
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 7207
Rear Cross-Member: Service and Repair Crossmember - Transmission
CROSSMEMBER - TRANSMISSION
Removal and Installation
1. Raise and support the vehicle.
2. Remove the transmission mount nuts. 3. Support the transmission.
4. Remove the transmission crossmember bolts and transmission crossmember. 5. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension to the OFF position. 2. Remove the wheel hub.
3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
4. Remove the bolt and position the brake hose aside.
5. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7211
6. Remove the nut and bolt.
^ Discard the nut.
7. Remove the three bolts.
8. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove and discard the nut.
9. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
NOTE: To separate the ball joint from the wheel knuckle, loosely install the nut and then tap on the
end of the stud.
Remove the nut and the wheel knuckle. ^
Discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7212
10. To install, reverse the removal procedure. 11. Check and, if necessary, align the front end.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair
Rear Knuckle: Service and Repair
Wheel Knuckle
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. Remove the wheel bearing.
2. Remove the springs, adjuster and the parking brake shoes.
3. Depress the tabs and detach the parking brake cable from the wheel knuckle.
4. Remove the nut and detach the toe link from the wheel knuckle.
^ Discard the nut.
5. Remove the nut and bolt.
^ Discard the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 7216
6. Remove the bolt, flag nut and the wheel knuckle.
^ Discard the flag nut.
7. If necessary, using a suitable press and adapters, remove the upper ball joint. 8. To install,
reverse the removal procedure.
^ Check and, if necessary, adjust the rear alignment.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair
Rear Knuckle Alignment Link: Service and Repair
TOE LINK
REMOVAL AND INSTALLATION
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove the nut and separate the toe link from the wheel knuckle.
4. Remove the nut and the toe link. 5. To install, reverse the removal procedure. 6. Check and, if
necessary, adjust the rear toe.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7224
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7225
Compressor/Pump Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7226
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Locations
Suspension Control Module: Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Locations > Page 7230
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Locations > Page 7231
Suspension Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Locations > Page 7232
Suspension Control Module: Service and Repair
Air Suspension Control Module
Removal and Installation
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery ground cable.
2. NOTE: The air suspension control module is mounted to the lower left side of the dash above
the parking brake control.
Disconnect the electrical connectors.
3. Pull back the dash padding to expose the module mounting nuts.
4. Remove the air suspension control module nuts.
5. 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 and pneumatic test be carried out.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height
Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose
Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height
Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 7242
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose
Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor
Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 7248
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 7249
Ride Height Sensor: Service and Repair
Suspension Height Sensor
Removal and Installation
NOTE: Front shown, rear similar.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the LH
quarter trim panel. 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. Disconnect the sensor arm.
3. Remove and discard the nuts (front height sensor).
4. Remove and discard the bolts (rear height sensor).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 7250
5. Disconnect the electrical connector.
6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle.
To install, reverse the removal procedure. ^
Calibrate the height sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 7254
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension
Mode Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension
Mode Switch > Component Information > Locations > Page 7258
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair
Stabilizer Link: Service and Repair
Stabilizer Bar and Link
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assemblies.
3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove the two nuts. ^
Discard the nuts.
4. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut.
Remove the two nuts and the stabilizer bar links. ^
Discard the nuts.
5. Remove the four nuts, brackets and the stabilizer bar.
6. NOTE: Inspect and, if necessary, install new bushings.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Dryer, Suspension Control > Component Information > Service and Repair
Air Dryer: Service and Repair
Air Suspension Compressor Drier
Removal and Installation
1. Remove the air compressor.
2. NOTE: Make sure that the drier O-ring does not remain inside of the compressor assembly.
Remove the air compressor drier. 1
Remove the screw.
2 Rotate 90 degrees counterclockwise to unlock, then remove the air compressor drier.
3. NOTE: Inspect the drier O-ring for damage and install a new O-ring as necessary.
NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
To install. reverse the removal Procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
Air Line Fluid Purge
Special Tool(s)
1. NOTE: If oil is present in the air lines, remove the air spring solenoids and inspect the solenoid
filters. If oil is present in a filter, install a new
solenoid and shock absorber.
Disconnect the air line at the air compressor drier.
2. Disconnect the air line at the RF and LF air spring solenoids. 3. Connect shop air line to the
disconnected air line (drier end) and blow out any fluid.
4. 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 spring solenoid.
5. Disconnect the air line at the RR and LR air spring solenoids. 6. Connect the shop air line (drier
end) to the disconnected air line and blow out any fluid.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7271
Air Line: Service and Repair Air Line Repair
Air Line Repair
1. Cut the line at the damaged area.
2. Trim the sleeve material from both ends of the damaged line.
3. Taper both ends of the tube by shaving or sanding it 3 mm (0.11 inch) from the tips.
4. Install the repair filling.
5. NOTE: Check system for leaks.
Inflate the air suspension system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 7275
Compressor/Pump: Service and Repair
Air Suspension Compressor
Removal and Installation
1. Remove the air suspension relay from the bracket. 2. Remove the windshield washer pump and
reservoir.
3. Compress the orange quick-connect lock ring inward, then pull the line outward from the air
drier.
4. Disconnect the air compressor electrical connector.
5. Remove the air compressor bracket bolts and remove the air compressor/drier assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 7276
6. If the bracket will be discarded, remove the air compressor from the bracket.
^ Remove and discard the three screws and washers.
^ Remove and discard the three rubber isolators from the air compressor.
^ Remove and discard the silencer (muffler) retaining screws and remove the silencer from the
bracket.
7. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
To install, reverse the removal procedure.
^
NOTE: Make sure that there are no objects trapped under or on the bracket.
Make sure that the air compressor is not in contact with any surrounding components that could
cause vibration noises.
NOTE: Make sure that the air compressor moves freely in the rubber isolators.
Make sure that the bracket has no deformations that could cause the three rubber isolators to load
against each other. If installing a new bracket from the kit, only use the new fasteners supplied as
instructed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7280
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7281
Compressor/Pump Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7282
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Damping Control Actuator > Component Information > Locations > Air Spring Solenoid Valve, Right/Left Front
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Damping Control Actuator > Component Information > Locations > Air Spring Solenoid Valve, Right/Left Front > Page 7287
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front > Page 7290
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front > Page 7291
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front > Page 7292
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair
Level Control Solenoid Valve: Service and Repair
Air Spring Solenoid Valve
Special Tool(s)
Material
Removal and Installation
WARNING: Do not remove an air spring under any circumstances when there is pressure in the air
spring. Do not remove any components supporting an air spring without either exhausting the air or
providing support for the air spring to prevent vehicle damage or personal injury.
NOTE: Front shown, rear similar.
1. If the air spring solenoid valve is functional, use the diagnostic tool to vent the appropriate air
spring(s).
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the LH
quarter trim panel. Failure to do so may result in unexpected inflation or deflation of the air springs
which may result in shifting of the vehicle during these operations.
Turn the air suspension switch to the OFF position.
3. Remove the wheel and tire assembly.
4. Disconnect the electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Page 7296
5. Compress the orange lock ring, then pull down on the air line and disconnect the air line.
6. CAUTION: Remove any dirt or other foreign material from the air spring assembly prior to
removing the air spring solenoid valve from the air
spring assembly.
Remove the air spring solenoid clip.
7. WARNING: The air spring solenoid valve has a two stage release. When removing a
non-functional solenoid and the air spring is
inflated, carefully rotate the solenoid counterclockwise until it reaches the first stage to release the
air from the air spring. Turn the solenoid to the second stage to remove the solenoid. Failure to
follow these instructions when removing a non-functional air spring solenoid can cause personal
injury or damage to components as high pressure air is vented uncontrolled.
Rotate the air spring solenoid and remove the solenoid.
8. NOTE: Inspect the O-ring for damage and install a new O-ring as necessary. Lightly lubricate the
solenoid seal area with silicone grease.
NOTE: After installing the solenoid, it is necessary to inflate the air suspension system.
NOTE: When installing the air spring solenoid, make sure that the electrical connector is positioned
away from the air spring.
NOTE: When installing the air lines, make sure the 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 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride
Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose
Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride
Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 7305
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose
Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor
Linkage Loose
TSB 06-15-10
08/07/06
AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may
exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or
height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may
occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning
to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In
addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front
pneumatic failure) or C1726 (air suspension rear pneumatic failure).
ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace
the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies,
even if they have not detached from the ball stud. Refer to the following Service Procedure.
SERVICE PROCEDURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 7311
NOTE
LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED
LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO
DISENGAGE FROM THE BALL STUDS.
NOTE
IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER
THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED
WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL
LINKAGES FOR THE SERVICE REPAIR.
1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM),
Section 204-05.
2. Discard the old linkage arms.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061510A 2003-2006 0.4 Hr.
Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic
Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5A967 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 7312
Ride Height Sensor: Service and Repair
Suspension Height Sensor
Removal and Installation
NOTE: Front shown, rear similar.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the LH
quarter trim panel. 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. Disconnect the sensor arm.
3. Remove and discard the nuts (front height sensor).
4. Remove and discard the bolts (rear height sensor).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 7313
5. Disconnect the electrical connector.
6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle.
To install, reverse the removal procedure. ^
Calibrate the height sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Locations
Suspension Control Module: Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Locations > Page 7317
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Locations > Page 7318
Suspension Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Locations > Page 7319
Suspension Control Module: Service and Repair
Air Suspension Control Module
Removal and Installation
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Disconnect the battery ground cable.
2. NOTE: The air suspension control module is mounted to the lower left side of the dash above
the parking brake control.
Disconnect the electrical connectors.
3. Pull back the dash padding to expose the module mounting nuts.
4. Remove the air suspension control module nuts.
5. 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 and pneumatic test be carried out.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Mode Switch > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Mode Switch > Component Information > Locations > Page 7323
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair
Suspension Strut / Shock Absorber: Service and Repair
Shock Absorber and Spring Assembly
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. 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. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. Remove and discard the nuts.
4. Remove the bolt and flag nut.
^ Discard the flag nut.
5. Remove the shock absorber and spring assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Page 7327
6. NOTE: For reference during assembly, index the upper mount, spring and shock absorber.
Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
7. While holding the shock rod, remove the nut and washer.
^ Remove the shock absorber.
^ Discard the nut.
8. Remove the upper mount, dust shield and insulator. 9. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical
Service Bulletins > Customer Interest for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump From Rear
When Shifting A/T
Torque Rod: Customer Interest A/T/Suspension - Clunk/Thump From Rear When Shifting A/T
TSB 05-16-1
08/22/05
CLUNK/GRIND/THUMP NOISE FROM REAR OF VEHICLE WHEN TRANSMISSION IS SHIFTED
- VEHICLES BUILT BEFORE 6/13/2005
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 6/13/2005, may exhibit a
clunk/grind/thump noise from the rear when the transmission is shifted, during a change in vehicle
direction or on acceleration. A vibration from the driveshaft/axle area may also be exhibited.
ACTION This noise may be due to the torque arm to rear axle housing attachment bolts becoming
loose. It may be necessary to replace the four (4) attachment bolts, and the torque arm if distorted.
The torque arm attaches at the front right side of the rear differential and the # 4 crossmember.
SERVICE PROCEDURE
1. Turn off the air suspension switch if equipped.
2. Raise vehicle, refer to Workshop Manual Section 100-02.
3. Using a suitable jack-stand, support the rear axle housing.
4. Remove the four (4) torque arm to rear axle housing attachment bolts. Clean both mating
surfaces.
5. Inspect the torque arm for distortion.
a. If no distortion is found, replace only the four (4) torque arm to axle housing bolts and tighten to
150 lb-ft (200 N.m).
(1) Remove jack.
(2) Lower the vehicle.
(3) Turn on the air suspension switch if equipped.
b. If distortion is found, replace the torque arm and the four (4) torque arm to axle housing bolts.
Refer to torque arm replacement procedure.
TORQUE ARM REPLACEMENT PROCEDURE
1. Remove front torque arm bolt and torque arm.
2. Install the new torque arm and front bolt, do not tighten at this time.
3. Install the four (4) new torque arm to axle assembly bolts and tighten to 150 lb-ft (200 N.m).
a. Loosen each bolt one revolution.
b. Re-tighten each bolt to 150 lb-ft. (200 N.m).
c. Tighten front torque arm bolt to 100 lb-ft. (135 N.m).
4. Remove jack.
5. Lower the vehicle.
6. Turn on the air suspension switch if equipped.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical
Service Bulletins > Customer Interest for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump From Rear
When Shifting A/T > Page 7336
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051601A 2005-2006 0.4 Hr.
Expedition/Navigator: Replace The Torque Arm To Axle Housing Bolts
051601B 2005-2006 0.5 Hr.
Expedition/Navigator: Replace The Torque Arm And Torque Arm Bolts
DEALER CODING
CONDITION
BASIC PART NO. CODE
4382 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical
Service Bulletins > Customer Interest for Torque Rod: > 05-16-10 > Aug > 05 > Suspension/Frame - Rear End
Clunk/Thump/Grind Noise
Torque Rod: Customer Interest Suspension/Frame - Rear End Clunk/Thump/Grind Noise
TSB 05-16-10
08/22/05
CLUNK/GRIND/THUMP NOISE - FRAME REPAIR PROCEDURE
FORD: 2003 Expedition 2005-2006 Expedition
LINCOLN: 2003 Navigator 2005-2006 Navigator
ISSUE Some 2003 Expedition/Navigator built 3/18/2003 through 9/3/2003 and 2005-2006 built
8/2/2004 to 6/13/2005 may exhibit a clunk/grind/thump noise from the rear of the vehicle. The
condition will occur when the transmission is shifted, the vehicle changes direction, or on
acceleration. Vehicles may also exhibit a vibration from the driveshaft/axle area. This may be due
to missing or damaged attachment bolts that secure the rear torque arm to the axle housing. In rare
cases, if symptoms are ignored and the bolts are allowed to completely disengage, the differential
may tip upwards allowing the driveshaft to make contact with the frame.
ACTION If frame damage is found, a service kit is available to repair and reinforce the frame. Refer
to the instruction sheet included in the kit.
Parts Block
OTHER APPLICABLE ARTICLES: 05-16-1
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
4612 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump
From Rear When Shifting A/T
Torque Rod: All Technical Service Bulletins A/T/Suspension - Clunk/Thump From Rear When
Shifting A/T
TSB 05-16-1
08/22/05
CLUNK/GRIND/THUMP NOISE FROM REAR OF VEHICLE WHEN TRANSMISSION IS SHIFTED
- VEHICLES BUILT BEFORE 6/13/2005
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 6/13/2005, may exhibit a
clunk/grind/thump noise from the rear when the transmission is shifted, during a change in vehicle
direction or on acceleration. A vibration from the driveshaft/axle area may also be exhibited.
ACTION This noise may be due to the torque arm to rear axle housing attachment bolts becoming
loose. It may be necessary to replace the four (4) attachment bolts, and the torque arm if distorted.
The torque arm attaches at the front right side of the rear differential and the # 4 crossmember.
SERVICE PROCEDURE
1. Turn off the air suspension switch if equipped.
2. Raise vehicle, refer to Workshop Manual Section 100-02.
3. Using a suitable jack-stand, support the rear axle housing.
4. Remove the four (4) torque arm to rear axle housing attachment bolts. Clean both mating
surfaces.
5. Inspect the torque arm for distortion.
a. If no distortion is found, replace only the four (4) torque arm to axle housing bolts and tighten to
150 lb-ft (200 N.m).
(1) Remove jack.
(2) Lower the vehicle.
(3) Turn on the air suspension switch if equipped.
b. If distortion is found, replace the torque arm and the four (4) torque arm to axle housing bolts.
Refer to torque arm replacement procedure.
TORQUE ARM REPLACEMENT PROCEDURE
1. Remove front torque arm bolt and torque arm.
2. Install the new torque arm and front bolt, do not tighten at this time.
3. Install the four (4) new torque arm to axle assembly bolts and tighten to 150 lb-ft (200 N.m).
a. Loosen each bolt one revolution.
b. Re-tighten each bolt to 150 lb-ft. (200 N.m).
c. Tighten front torque arm bolt to 100 lb-ft. (135 N.m).
4. Remove jack.
5. Lower the vehicle.
6. Turn on the air suspension switch if equipped.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump
From Rear When Shifting A/T > Page 7346
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051601A 2005-2006 0.4 Hr.
Expedition/Navigator: Replace The Torque Arm To Axle Housing Bolts
051601B 2005-2006 0.5 Hr.
Expedition/Navigator: Replace The Torque Arm And Torque Arm Bolts
DEALER CODING
CONDITION
BASIC PART NO. CODE
4382 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Torque Rod: > 05-16-10 > Aug > 05 > Suspension/Frame - Rear End
Clunk/Thump/Grind Noise
Torque Rod: All Technical Service Bulletins Suspension/Frame - Rear End Clunk/Thump/Grind
Noise
TSB 05-16-10
08/22/05
CLUNK/GRIND/THUMP NOISE - FRAME REPAIR PROCEDURE
FORD: 2003 Expedition 2005-2006 Expedition
LINCOLN: 2003 Navigator 2005-2006 Navigator
ISSUE Some 2003 Expedition/Navigator built 3/18/2003 through 9/3/2003 and 2005-2006 built
8/2/2004 to 6/13/2005 may exhibit a clunk/grind/thump noise from the rear of the vehicle. The
condition will occur when the transmission is shifted, the vehicle changes direction, or on
acceleration. Vehicles may also exhibit a vibration from the driveshaft/axle area. This may be due
to missing or damaged attachment bolts that secure the rear torque arm to the axle housing. In rare
cases, if symptoms are ignored and the bolts are allowed to completely disengage, the differential
may tip upwards allowing the driveshaft to make contact with the frame.
ACTION If frame damage is found, a service kit is available to repair and reinforce the frame. Refer
to the instruction sheet included in the kit.
Parts Block
OTHER APPLICABLE ARTICLES: 05-16-1
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
4612 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications
Wheel bearing-to-knuckle bolts
.............................................................................................................................................................
200 Nm (148 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 7354
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp 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.
3. If the wheel (hub) is loose or does not rotate freely, install a new wheel hub.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position.
2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel and tire
assembly.
4. Remove the bolt and detach the retainers.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7357
6. Remove the brake disc.
7. Remove the dust cap.
8. Remove and discard the nut.
9. Remove the bolts and the wheel bearing and hub assembly.
10. CAUTION: If the original wheel bearing and hub is being reinstalled, make sure to install a new
O-ring.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7358
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating.
Remove and discard the rear axle wheel hub retainer and the washer
4. Using a suitable hub puller, separate the outboard CV joint from the wheel hub.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7359
6. Remove the brake disc.
7. Disconnect the wheel speed sensor electrical connector and detach the retainer.
8. Remove the bolt and detach the retainers.
9. Remove the bolts, the wheel bearing and the wheel speed sensor as an assembly.
^ Route the sensor wiring through the access hole in the brake shield.
^ Discard the bolts.
10. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Rear axle wheel hub retainer ...............................................................................................................
................................................... 345 Nm (254 lb. ft.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component
Information > Locations
Wheel Hub Lock Solenoid: Locations
INTEGRATED WHEEL ENDS SOLENOID
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component
Information > Locations > Page 7367
Wheel Hub Lock Solenoid: Diagrams
INTEGRATED WHEEL ENDS SOLENOID
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING:
- The electrical power to the air suspension system must be shut down prior to hoisting, jacking or
towing an air suspension vehicle. This can be accomplished by turning off the air suspension
switch located in the LH rear quarter trim panel area. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
- Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause
the vehicle to move.
- Support the vehicle prior to carrying out any procedure requiring the vehicle to be jacked off the
ground.
- Make sure the jack and jack stands are correctly located to prevent the vehicle from falling.
- Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack.
CAUTION:
- Never use a halfshaft as a lifting point.
- If equipped with retractable running board, disable the system through the instrument cluster
controls.
Jacking Points - Front
Jacking Points - Front
The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and
wheel assembly.
Jacking Points - Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 7372
Jacking Points - Rear
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Do not use the rear control arms as a lifting point.
The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire
and wheel assembly.
LIFTING
WARNING: The electrical power to the air suspension system must be shut down prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel area. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
CAUTION: Damage to suspension, exhaust and steering linkage components can occur if care is
not exercised when positioning the hoist adapters prior to lifting the vehicle.
Lifting Points - Twin Post Hoist
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 7373
Lifting Points - Twin Post Hoist
Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated.
Lifting Points - Drive On Hoist
Lifting Points - Drive On Hoist
The vehicle is supported by tires and suspension components.
Lifting Points - Floor Jack, Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 7374
Lifting Points - Floor Jack, Front
The front can be lifted using a floor jack under the front control arm directly below the shock.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Module > Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Module > Component Information > Application and ID > Page 7379
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Page 7384
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Page 7385
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Page 7386
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Page 7387
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Description and Operation
Low Tire Pressure Indicator: Description and Operation
TIRE PRESSURE MONITORING SYSTEM (TPMS)
When the Tire Pressure Monitoring System warning light is lit, one or more of your tires is
significantly under-inflated. You should stop and check your tires as soon as possible, and inflate
them to the proper pressure as indicated on the vehicle's tire information placard (label). Driving on
a significantly under-inflated tire causes the tire to overheat and can eventually lead to tire failure.
Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling
and stopping ability. Even if your vehicle is equipped with a Tire Pressure Monitoring System, it is
still Important that you manually check the inflation pressure of your tires regularly. Each tire,
including the spare, should be checked monthly when cold and set to the recommended inflation
pressure which can be found on either the tire label or certification label which is located on the
B-Pillar or the edge of the driver's door.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Description and Operation > Page 7392
Low Tire Pressure Indicator: Service and Repair
Sensor Training (Reset Procedure)
NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones and remote
transmitters, power inverters and portable entertainment equipment.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to
the RUN position three times, ending in the RUN position. Do not wait more than one minute
between each key cycle.
3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than one minute
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LF TIRE", place the magnet on the valve stem of the LF tire pressure sensor. The horn will
sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the VSM (TPMS module integral to VSM) does not recognize any one of the four tire
pressure sensors during the tire training procedure, the horn will sound twice and the message
center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be
repeated.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will display "TIRE TRAINING MODE COMPLETE".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module
> Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module
> Component Information > Application and ID > Page 7396
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Page 7400
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Page 7401
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Page 7402
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Page 7403
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns
Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7412
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7413
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7414
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7420
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7421
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7422
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications
Wheel bearing-to-knuckle bolts
.............................................................................................................................................................
200 Nm (148 ft. lbs.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 7426
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp 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.
3. If the wheel (hub) is loose or does not rotate freely, install a new wheel hub.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position.
2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel and tire
assembly.
4. Remove the bolt and detach the retainers.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7429
6. Remove the brake disc.
7. Remove the dust cap.
8. Remove and discard the nut.
9. Remove the bolts and the wheel bearing and hub assembly.
10. CAUTION: If the original wheel bearing and hub is being reinstalled, make sure to install a new
O-ring.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7430
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Removal and Installation
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel and tire
assembly.
3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating.
Remove and discard the rear axle wheel hub retainer and the washer
4. Using a suitable hub puller, separate the outboard CV joint from the wheel hub.
5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can
result.
Remove the bolts, and position the caliper, pads and anchor plate aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7431
6. Remove the brake disc.
7. Disconnect the wheel speed sensor electrical connector and detach the retainer.
8. Remove the bolt and detach the retainers.
9. Remove the bolts, the wheel bearing and the wheel speed sensor as an assembly.
^ Route the sensor wiring through the access hole in the brake shield.
^ Discard the bolts.
10. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Rear axle wheel hub retainer ...............................................................................................................
................................................... 345 Nm (254 lb. ft.)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid >
Component Information > Locations
Wheel Hub Lock Solenoid: Locations
INTEGRATED WHEEL ENDS SOLENOID
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid >
Component Information > Locations > Page 7439
Wheel Hub Lock Solenoid: Diagrams
INTEGRATED WHEEL ENDS SOLENOID
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Page 7443
Wheel Fastener: Service and Repair
Wheel Studs
Special Tool(s)
Special Tool(s)
Removal
WARNING: The electrical power to the air suspension system, must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the LH rear quarter trim panel. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. Remove the wheel bearing.
2. CAUTION: Never use a hammer to remove a wheel stud. Damage to the wheel hub can result.
Place the wheel hub in a soft jawed vice and using the special tool remove the wheel stud
Installation
1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the flange can be
stripped.
NOTE: Do not use the wheel nut that came with the vehicle
Install the washers and wheel nut on the wheel stud and tighten the wheel nut until the stud seats
against the flange Discard the wheel nut
2. Install the wheel bearing.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Mode Door Actuator, Rear
View 151-34 (Auxiliary Climate Control)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Mode Door Actuator, Rear > Page 7450
View 151-34 (Auxiliary Climate Control)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Mode Door Actuator, Rear > Page 7451
View 151-33 (Climate Control System)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7454
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7455
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7456
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7457
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Auxiliary Temperature Blend Door Actuator
Air Door Actuator / Motor: Service and Repair Auxiliary Temperature Blend Door Actuator
Air Distribution
AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR - AIR DISTRIBUTION
Removal and Installation
1. Remove the RH quarter trim panel cup holder and access panel.
2. Remove the screws.
3. Disconnect the blend door actuator electrical connector. 4. To install, reverse the removal
procedure.
Temperature
AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR - TEMPERATURE
Removal and Installation
1. Remove the RH quarter trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 7460
2. Remove the auxiliary temperature blend door actuator.
1 Disconnect the temperature blend door actuator electrical connector.
2 Remove the screws.
3 Remove the auxiliary temperature blend door actuator.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 7461
Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator
RH
TEMPERATURE BLEND DOOR ACTUATOR - RH
Removal and Installation
1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/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
2. Remove the temperature blend door actuator.
1 Disconnect the temperature blend door actuator electrical connector.
2 Remove the screws.
3 Remove the temperature blend door actuator.
3. To install, reverse the removal procedure.
LH
TEMPERATURE BLEND DOOR ACTUATOR - LH
Removal and Installation
1. Remove the plenum chamber.
2. Remove the screws and the floor duct.
3. Remove the temperature blend door actuator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 7462
1 Disconnect the temperature blend door actuator electrical connector.
2 Remove the screws.
3 Remove the temperature blend door actuator.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 7463
Air Door Actuator / Motor: Service and Repair Vacuum Control Motor
Air Inlet Door
VACUUM CONTROL MOTOR - AIR INLET DOOR
Removal and Installation
1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim,
Dashboard/Instrument Panel, Service and Repair, Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Installation
2. Disconnect the vacuum connector.
3. Remove the screws and the air inlet door vacuum control motor. 4. To install, reverse the
removal procedure.
Floor/Defrost Door
VACUUM CONTROL MOTOR - FLOOR/DEFROST DOOR
Removal and Installation
1. Remove the bolts and position aside the accelerator pedal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 7464
2. Remove the floor/defrost door vacuum control motor.
1 Disconnect the vacuum connector.
2 Remove the screws.
3 Rotate the floor/defrost door vacuum control motor to clear the retaining arm.
3. Remove the floor/defrost door vacuum control motor. 4. To install, reverse the removal
procedure.
Panel Door
VACUUM CONTROL MOTOR - PANEL DOOR
Removal and Installation
1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim,
Dashboard/Instrument Panel, Service and Repair, Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Installation
2. Remove the panel door vacuum control motor.
1 Disconnect the vacuum connector.
2 Remove the screws.
3 Rotate the panel door vacuum control motor to clear the retaining arm.
- Remove the panel door vacuum control motor.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 7473
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 5 (2005))
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 7474
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 5 (2005))
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 5 (2005))
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 7480
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 5 (2005))
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 7481
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct
Air Duct: Service and Repair Floor Duct
FLOOR DUCT
Removal and Installation
1. Remove the plenum chamber.
2. Remove the screws and remove the floor duct. 3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 7484
Air Duct: Service and Repair Instrument Panel Air Distribution Ducts
INSTRUMENT PANEL AIR DISTRIBUTION DUCTS
Disassembly and Assembly
1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/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
2. Remove the screws and remove the RH demister.
3. Remove the screws and remove the defroster duct.
4. Remove the screws and remove the LH demister.
5. Remove the screws and remove the LH panel duct.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 7485
6. Remove the RH panel duct screws.
7. Remove the center panel duct screws and remove the center and RH panel ducts. 8. To
assemble, reverse the disassembly procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 7486
Air Duct: Service and Repair Rear Footwell Duct
REAR FOOTWELL DUCT
Removal and Installation
1. Remove the front seats. 2. Remove the center floor console.
3. NOTE: RH cowl trim and sill plate shown, LH similar.
Remove the RH and LH cowl trim panel and sill plates.
4. Fold back the carpet to completely uncover the rear footwell duct.
5. Remove the pin-type retainers and remove the duct. 6. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > Customer Interest for Air Register: > 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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > Customer Interest for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents >
Page 7495
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > Customer Interest for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents >
Page 7496
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Register: > 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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From
Dash Vents > Page 7502
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Register: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From
Dash Vents > Page 7503
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service
Bulletins > Page 7504
Air Register: Service and Repair
REGISTER
Removal and Installation
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. 3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7508
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7509
Ambient Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7510
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
Removal and Installation
Expedition
1. Remove the radiator sight shield.
1 Remove the pin-type retainers.
2 Remove the radiator sight shield.
All vehicles
2. Detach the ambient temperature sensor pin-type retainer.
3. Disconnect the electrical connector and remove the ambient temperature sensor. 4. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Locations
View 151-34 (Auxiliary Climate Control)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Locations > Page 7515
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Front Blower Motor Relay
Blower Motor Relay: Locations Front Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Front Blower Motor Relay > Page 7520
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Front Blower Motor Relay > Page 7521
Blower Motor Relay: Locations Rear Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Front Blower Motor Relay > Page 7522
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Front Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Front Blower Motor Relay > Page 7525
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Front Blower Motor Relay
Blower Motor Relay: Testing and Inspection Front Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Front Blower Motor Relay > Page 7528
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Front Blower Motor Relay > Page 7529
Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Front Blower Motor Relay > Page 7530
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Auxiliary Blower Motor Resistor Assembly
View 151-34 (Auxiliary Climate Control)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Auxiliary Blower Motor Resistor Assembly > Page 7535
View 151-33 (Climate Control System)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Blower Motor Resistor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Blower Motor Resistor > Page 7538
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Blower Motor Resistor
Blower Motor Resistor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Blower Motor Resistor > Page 7541
Auxiliary Blower Motor Resistor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Page 7542
Blower Motor Resistor: Service and Repair
BLOWER MOTOR RESISTOR
Removal and Installation
1. Remove the RH quarter trim panel access panel.
2. Remove the blower motor resistor.
1 Disconnect the blower motor resistor electrical connector.
2 Remove the screws and the blower motor resistor.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and
Repair > Blower Motor Switch
Blower Motor Switch: Service and Repair Blower Motor Switch
BLOWER MOTOR SWITCH
Removal and Installation
1. Remove the climate control assembly. 2. Pull and remove the blower motor switch knob.
3. Release the clips and remove the blower motor switch. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and
Repair > Blower Motor Switch > Page 7547
Blower Motor Switch: Service and Repair Blower Motor Speed Control
BLOWER MOTOR SPEED CONTROL
Removal and Installation
1. Remove the RH lower instrument panel insulator.
2. Remove the blower motor speed control.
1 Remove the screw.
2 Remove the blower motor speed control.
3 Disconnect the blower motor speed control electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Diagrams > In-Vehicle Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Diagrams > In-Vehicle Temperature Sensor > Page 7556
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Diagrams > Page 7557
In-Vehicle Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Service and Repair > In-Vehicle Temperature Sensor
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor
IN-VEHICLE TEMPERATURE SENSOR
Removal and Installation
1. Remove the screws and the instrument cluster finish panel.
- Disconnect the electrical connectors.
2. Disconnect the aspirator hose and the in-vehicle temperature sensor electrical connector.
3. Remove the screws and the in-vehicle temperature sensor. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Service and Repair > In-Vehicle Temperature Sensor > Page 7560
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity
Sensor
IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR
Removal and Installation
1. Remove the in-vehicle temperature and humidity sensor trim cover.
2. Disconnect the aspirator hose and the in-vehicle temperature and humidity sensor electrical
connector.
3. Remove the screws and the in-vehicle temperature and humidity sensor. 4. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Magnetic Clutch
Air gap clearance..................................................................................................................................
...................................0.35-0.75 mm (0.014-0.030 in)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7565
Compressor Clutch: Adjustments
AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT
1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C
clutch pulley. 2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove
spacers between the clutch plate hub and the compressor shaft
until the clearance is within specification.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7566
Compressor Clutch: Service and Repair
CLUTCH AND CLUTCH FIELD COIL
Special Tool(s)
Special Tool(s)
Removal
1. Remove the A/C compressor.
2. Remove the A/C clutch disc and hub retaining nut.
1 Using the special tool, hold the A/C clutch disc and hub.
2 Remove the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7567
3. Remove the A/C clutch disc and hub.
4. Remove the A/C clutch disc and hub spacer.
5. Remove the A/C clutch pulley snap-ring.
6. CAUTION: Do not use air tools. Damage to the A/C clutch pulley may result.
Using the special tool, remove the A/C clutch pulley.
7. Note the location of the A/C clutch field coil connector.
8. Remove the A/C clutch field coil snap-ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7568
9. Remove the A/C clutch field coil.
Installation
1. NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless
obvious signs of damage are found. If excessive
grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed
together. Otherwise, each component can be installed individually where needed.
Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for
damage. Inspect for physical damage, including cracked or melted components or discoloration due to
excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor
pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C compressor, A/C clutch field coil, and the A/C clutch pulley mounting surfaces.
3. CAUTION: There is an indexing locator on the A/C clutch field coil mounting surface. Make sure
it is correctly aligned during
installation to the A/C compressor.
Align and install the A/C clutch field coil to the A/C compressor.
4. Install the A/C clutch field coil snap-ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7569
5. NOTE: The A/C clutch pulley fits tightly to the A/C compressor. It must be aligned correctly for
installation.
Install the A/C clutch pulley.
6. NOTE: The snap-ring must be installed with the bevel side up.
Install the A/C clutch pulley snap-ring with the bevel side up.
7. Install one nominal thickness A/C clutch plate spacer onto the A/C compressor shaft.
8. Install the A/C clutch disc and hub.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7570
9. Install the clutch disc and hub retaining nut.
1 Using the special tool, hold the A/C clutch disc and hub.
2 Tighten the nut.
10. Measure and adjust (if necessary) the A/C clutch air gap by removing or adding A/C clutch disc
and hub spacers. 11. Install the A/C compressor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 7574
Compressor Clutch Coil: Service and Repair
CLUTCH AND CLUTCH FIELD COIL
Special Tool(s)
Special Tool(s)
Removal
1. Remove the A/C compressor.
2. Remove the A/C clutch disc and hub retaining nut.
1 Using the special tool, hold the A/C clutch disc and hub.
2 Remove the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 7575
3. Remove the A/C clutch disc and hub.
4. Remove the A/C clutch disc and hub spacer.
5. Remove the A/C clutch pulley snap-ring.
6. CAUTION: Do not use air tools. Damage to the A/C clutch pulley may result.
Using the special tool, remove the A/C clutch pulley.
7. Note the location of the A/C clutch field coil connector.
8. Remove the A/C clutch field coil snap-ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 7576
9. Remove the A/C clutch field coil.
Installation
1. NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless
obvious signs of damage are found. If excessive
grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed
together. Otherwise, each component can be installed individually where needed.
Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for
damage. Inspect for physical damage, including cracked or melted components or discoloration due to
excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor
pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C compressor, A/C clutch field coil, and the A/C clutch pulley mounting surfaces.
3. CAUTION: There is an indexing locator on the A/C clutch field coil mounting surface. Make sure
it is correctly aligned during
installation to the A/C compressor.
Align and install the A/C clutch field coil to the A/C compressor.
4. Install the A/C clutch field coil snap-ring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 7577
5. NOTE: The A/C clutch pulley fits tightly to the A/C compressor. It must be aligned correctly for
installation.
Install the A/C clutch pulley.
6. NOTE: The snap-ring must be installed with the bevel side up.
Install the A/C clutch pulley snap-ring with the bevel side up.
7. Install one nominal thickness A/C clutch plate spacer onto the A/C compressor shaft.
8. Install the A/C clutch disc and hub.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 7578
9. Install the clutch disc and hub retaining nut.
1 Using the special tool, hold the A/C clutch disc and hub.
2 Tighten the nut.
10. Measure and adjust (if necessary) the A/C clutch air gap by removing or adding A/C clutch disc
and hub spacers. 11. Install the A/C compressor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information >
Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7585
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7586
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7587
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING CLUTCH RELAY (A/CCR)
NOTE: The PCM PIDs WAC and WACF are used to monitor the A/CCR output.
The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally
open. There is no direct electrical connection between the A/C switch or EATC module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the communications network). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as 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 A/CCR output, closing the relay contacts and sending
voltage to the A/C clutch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7588
Compressor Clutch Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7589
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Testing and
Inspection
Condenser HVAC: Testing and Inspection
A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST
1. Recover the refrigerant.
2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to
the core tubes.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without
shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to
the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off
valve does not open.
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C
evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before replacing the A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Testing and
Inspection > Page 7593
Condenser HVAC: Service and Repair
CONDENSER CORE
Removal and Installation
NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
1. Recover the refrigerant. 2. Remove the upper radiator sight shield.
3. Remove the nuts and disconnect the condenser line fittings.
- Discard the O-ring seals.
4. NOTE: LH radiator bracket shown; RH similar.
Remove the bolts and the RH and LH radiator brackets.
5. NOTE: RH condenser core bracket shown; LH similar.
Remove the bolt and the RH and LH condenser core brackets.
6. Remove the condenser core.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Testing and
Inspection > Page 7594
7. If a new condenser core is to be installed, transfer the air deflectors from the old unit to the new
unit. 8. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
9. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Auxiliary Function Selector Switch Assembly, Front
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Auxiliary Function Selector Switch Assembly, Front > Page 7599
View 151-24 (Centre Console)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Auxiliary Function Selector Switch Assembly, Front > Page 7600
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Auxiliary Function Selector Switch Assembly, Front > Page 7601
View 151-33 (Climate Control System)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views
Control Assembly: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views > Page 7604
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views > Page 7605
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views > Page 7606
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Function Selector Switch
Function Selector Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Function Selector Switch > Page 7609
Front Auxiliary Climate Control Assembly
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Function Selector Switch > Page 7610
Real Auxiliary Climate Control Assembly
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly
Control Assembly: Service and Repair Auxiliary Climate Control Assembly
Front
AUXILIARY CLIMATE CONTROL ASSEMBLY - FRONT
Removal and Installation
All vehicles
1. NOTE: Vehicle with moonroof shown, vehicle without moonroof similar.
Disengage the clips and remove the overhead console. Disconnect the electrical connectors.
Vehicles with moonroof
2. Remove the screws and the map lights.
All vehicles
3. NOTE: Vehicle with moonroof shown, vehicle without moonroof similar.
Remove the screws and the front auxiliary climate control assembly.
4. To install, reverse the removal procedure.
Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly > Page 7613
AUXILIARY CLIMATE CONTROL ASSEMBLY - REAR
Removal and Installation
Navigator
1. Open the front floor console cover and remove the screws.
2. Open the cup holder and remove the screw.
All vehicles
3. NOTE: Navigator shown, Expedition similar.
Disengage the clips and remove the floor console rear finish panel. Disconnect the electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly > Page 7614
4. Remove the screws and the rear auxiliary climate control assembly. 5. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly > Page 7615
Control Assembly: Service and Repair Climate Control Assembly
Manual
CLIMATE CONTROL ASSEMBLY - MANUAL
Removal and Installation
1. Remove the screws and the instrument cluster finish panel.
- Disconnect the electrical connectors.
2. Remove the screws and the climate control assembly. 3. To install, reverse the removal
procedure.
EATC
CLIMATE CONTROL ASSEMBLY - EATC
Removal and Installation
Navigator 1. Disconnect the negative battery cable.
2. Detach and position the switch housing aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly > Page 7616
3. Detach the shift lever cover.
- Disconnect the electrical connector.
4. Remove the center console trim panel.
1 Remove the screws.
2 Disengage the four clips.
3 Remove the center console trim panel.
5. Disconnect the electrical connectors and remove the screws.
6. Remove the center instrument panel finish panel.
1 Open the audio unit cover to the full open position.
2 Disengage the four clips.
- Disconnect the electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly > Page 7617
Expedition 7. Apply the parking brake and place the gear selector in (1). 8. Disconnect the negative
battery cable.
9. Remove the screws and the instrument cluster finish panel.
- Disconnect the electrical connectors.
All vehicles
10. NOTE: Navigator shown, Expedition similar.
Remove the screws and the climate control assembly.
11. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Auxiliary Climate Control Assembly > Page 7618
Control Assembly: Service and Repair Function Selector Switch
FUNCTION SELECTOR SWITCH
Removal and Installation
1. Remove the manual climate control assembly. 2. Pull and remove the function selector knob.
3. Release the clips and remove the function selector switch. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 7622
Control Module HVAC: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 7623
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling
Coupler HVAC: Service and Repair Spring Lock Coupling
SPRING LOCK COUPLING
Remover, Refrigerant Coupling Spring
Special Tool(s)
Disconnect
1. Remove the spring lock coupling clip, if equipped.
2. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches
across the O-ring seal grooves, resulting in
refrigerant leaks.
Push the tool into the cage opening to release the female fitting from the spring lock coupling
spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool.
3. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring;
this can cause axial scratches across
the O-ring seal grooves resulting in refrigerant leaks.
Remove the spring lock coupling spring with a small hooked wire.
Cleaning
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7628
1. Fabricate a cleaning tool from a 1/8-inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions
corresponding to the coupling size.
3. Assemble the pad to the tool. 4. Coat the abrasive pad with mineral oil. 5. Roll the pad on the
tool and install it in a variable speed drill motor.
6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to
prevent axial scratches which may cause
future leaks.
Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free
of scratches or foreign material.
7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves
and scratches are still present, install a new component.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7629
9. Clean the O-ring seal grooves with a 300-mm (12-inch) length of natural fiber string.
- Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint-free cloth.
Connect
1. Install the spring lock coupling spring.
2. Lubricate the inside of the coupling with mineral oil.
3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those
specified in the Ford Master Parts Catalog may
result in intermittent leakage during vehicle operation.
Install the O-ring seals. Lubricate the O-ring seals with mineral oil.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7630
4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling
spring snaps over the flared end of the female
fitting.
5. Install the spring lock coupling clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7631
Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting
AIR CONDITIONING LINE (PEANUT) FITTING
Disconnect
1. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting.
Remove the nut and separate the 2 halves of the peanut fitting.
2. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches
across the O-ring seal groove, resulting in
refrigerant leaks.
Remove the O-ring seal with a non-metallic tool.
Connect
1. Clean all dirt or foreign material from the fittings.
2. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those
specified in the Ford Master Parts Catalog may
result in intermittent leakage during vehicle operation.
Install the O-ring seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7632
3. NOTE: When correctly assembled, the male and female fittings should be flush.
Assemble the male and female fittings together.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 05-8-7 > May > 05 > A/C - Water Leaks Onto Passenger Compartment Floor
Evaporator Case: Customer Interest A/C - Water Leaks Onto Passenger Compartment Floor
TSB 05-8-7
05/02/05
WATER LEAK INTO PASSENGER COMPARTMENT FLOOR AND/OR RATTLE NOISE FROM
DASH
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built 8/01/2004 through 1/17/2005, may exhibit a
water (condensation) leak into the passenger compartment floor and/or a rattle noise coming from
the dash. This may be due to the evaporator case lower stud and nut being loose allowing water to
seep past the seal between the evaporator case and the drain tube.
ACTION
Tighten the nut that attaches the evaporator case to the stud to 42 lb-in (4.8 N.m) (Figure 1).
Ensure that the case is tight to the drain tube seal. The case stud and nut can be accessed from
under the dash by pulling the carpet back on the passenger side floor.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050807A 2005 Expedition/Navigator 0.2 Hr.
Tighten The Lower Evaporator Case Stud
DEALER CODING
CONDITION
BASIC PART NO. CODE
19B555 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-8-7 > May > 05 > A/C - Water Leaks Onto Passenger Compartment Floor
Evaporator Case: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Compartment
Floor
TSB 05-8-7
05/02/05
WATER LEAK INTO PASSENGER COMPARTMENT FLOOR AND/OR RATTLE NOISE FROM
DASH
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built 8/01/2004 through 1/17/2005, may exhibit a
water (condensation) leak into the passenger compartment floor and/or a rattle noise coming from
the dash. This may be due to the evaporator case lower stud and nut being loose allowing water to
seep past the seal between the evaporator case and the drain tube.
ACTION
Tighten the nut that attaches the evaporator case to the stud to 42 lb-in (4.8 N.m) (Figure 1).
Ensure that the case is tight to the drain tube seal. The case stud and nut can be accessed from
under the dash by pulling the carpet back on the passenger side floor.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050807A 2005 Expedition/Navigator 0.2 Hr.
Tighten The Lower Evaporator Case Stud
DEALER CODING
CONDITION
BASIC PART NO. CODE
19B555 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set > Page 7651
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106
and P2135 Set > Page 7657
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Page 7658
Evaporator Case: Service and Repair
AUXILIARY CLIMATE CONTROL HOUSING
Removal and Installation
1. WARNING: Do not open the cooling system while it is hot or while the engine is running. Failure
to follow these instructions can result
in personal injury.
Recover the refrigerant.
2. Remove the RH quarter trim panel. Refer to: Body and Frame, Interior Moulding/Trim, Trim
Panel, Service and Repair, See: Body and
Frame/Interior Moulding / Trim/Trim Panel/Service and Repair
3. Detach the upper air duct from the auxiliary housing.
4. Remove the bolts and the auxiliary line bracket.
5. Disconnect the heater hoses.
1 Using suitable tools, clamp off the heater hoses.
2 Disconnect the heater hoses.
6. Disconnect the drain hose.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Page 7659
7. Disconnect the blower motor and blower motor resistor electrical connectors.
8. Disconnect the electrical actuator electrical connectors.
9. Remove the bolt.
10. Remove the bolt and the auxiliary climate control housing. 11. To install, reverse the removal
procedure.
- Install new O-ring seals.
- Clean and lubricate the coolant hoses with plain water only if needed.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Fill the engine coolant level. 13. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Core: > 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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash
Vents > Page 7668
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash
Vents > Page 7669
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing
From Dash Vents > Page 7675
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing
From Dash Vents > Page 7676
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Page 7677
Evaporator Core: Testing and Inspection
A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST
1. Recover the refrigerant.
2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to
the core tubes.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without
shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to
the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off
valve does not open.
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C
evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before replacing the A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
> Air Conditioning
Evaporator Core: Service and Repair Air Conditioning
EVAPORATOR CORE
Removal and Installation
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new receiver drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver drier.
- A new evaporator core seal is supplied as a kit with the evaporator core service part. Failure to
install this seal, or failure to install it correctly, will result in air bypassing the evaporator core and
loss of cooling efficiency.
1. Remove the plenum chamber.
2. Remove the dash panel seal. 3. Detach the wire harness from the evaporator core cover.
4. Disconnect the air inlet vacuum control motor vacuum connector.
5. Remove the screws and detach the blower resistor or blower motor speed control and wire
harness from the plenum chamber.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
> Air Conditioning > Page 7680
6. Remove the four bottom evaporator core cover screws.
7. Remove the screws and position the heater core cover aside.
8. Remove the five upper evaporator core cover screws.
9. Remove the remaining upper evaporator core cover screws and the evaporator core cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
> Air Conditioning > Page 7681
10. Remove the evaporator core. 11. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
> Air Conditioning > Page 7682
Evaporator Core: Service and Repair Auxiliary Climate Control
EVAPORATOR CORE
Removal and Installation
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
1. Remove the auxiliary climate control housing.
2. Disconnect the A/C fittings and remove the thermostatic expansion valve (TXV).
- Discard the O-ring seals.
3. Remove the screws and the evaporator/heater core access cover. 4. Remove the A/C
evaporator core. 5. To install, reverse the removal procedure.
- Install new O-ring seals.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto
Passenger Front Floor
Evaporator Drain Tube: Customer Interest A/C - Water Leaks Onto Passenger Front Floor
TSB 05-20-7
10/17/05
A/C CONDENSATION LEAKING ONTO THE PASSENGER FRONT FLOOR
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
ISSUE Some 2005-2006 Expedition and Navigator vehicles may exhibit water leaking on to the
passenger floor from the NC plenum drain tube area.
ACTION Refer to the following Service Procedure to determine if the water leak is from the air
conditioning drain tube and repair as necessary.
SERVICE PROCEDURE
1. Turn off air suspension, if equipped.
2. Verify the leak is from the HVAC case drain seal and not from another source. Pull back the
carpet on the passenger floorboard and feel the HVAC drain tube seal for water (Figure 1A-1B).
a. If signs of water or moisture are present continue on with the TSB.
b. If there are no signs of water or moisture at the drain tube seal, follow normal diagnosis and
repair procedures.
3. Expedition only: Open hood and remove transmission dip stick.
4. Navigator only: Use Message Center to position running boards in the extended position (out
setting). Refer to Owners Guide, drivers control
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto
Passenger Front Floor > Page 7691
section for more information.
5. Remove the right front wheel following Workshop Manual, Section 204-04 procedure.
6. Remove right front fender splash shield.
7. Expedition only: Remove transmission dipstick tube from vehicle.
8. Pull back the engine compartment dash panel insulator far enough to expose the HVAC drain
tube (Figure 2B) by removing the push pin to the right of the drain (Figure 2A).
9. Push elbow (P/N F3LY-6A614-A) onto drain tube to install. Make sure the short end of the elbow
is pushed onto the drain tube, and the long end is pointed straight down (Figure 3). Only water may
be used to aid in pushing the elbow onto the drain tube. (Do not use soap or petroleum products on
the elbow).
10. Re-seat the engine compartment dash panel insulator and replace the push pin.
11. Expedition only: Install transmission dipstick and tube.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto
Passenger Front Floor > Page 7692
12. Verify the repair by ensuring condensation is dripping outside the vehicle and not running inside
onto the passenger floorboard.
13. Replace the right front fender splash shield and wheel.
14. Turn air suspension back on, if equipped.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052007A 2005-2006 Expedition: 0.9 Hr
Install Extension On Evaporator Drain (Do not use with 7228A)
052007B 2005-2006 Navigator: 0.7 Hr
Install Extension On Evaporator Drain (Do not use with 7228A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19B739 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-8-7 > May > 05 > A/C - Water Leaks Onto Passenger
Compartment Floor
Evaporator Drain Tube: Customer Interest A/C - Water Leaks Onto Passenger Compartment Floor
TSB 05-8-7
05/02/05
WATER LEAK INTO PASSENGER COMPARTMENT FLOOR AND/OR RATTLE NOISE FROM
DASH
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built 8/01/2004 through 1/17/2005, may exhibit a
water (condensation) leak into the passenger compartment floor and/or a rattle noise coming from
the dash. This may be due to the evaporator case lower stud and nut being loose allowing water to
seep past the seal between the evaporator case and the drain tube.
ACTION
Tighten the nut that attaches the evaporator case to the stud to 42 lb-in (4.8 N.m) (Figure 1).
Ensure that the case is tight to the drain tube seal. The case stud and nut can be accessed from
under the dash by pulling the carpet back on the passenger side floor.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050807A 2005 Expedition/Navigator 0.2 Hr.
Tighten The Lower Evaporator Case Stud
DEALER CODING
CONDITION
BASIC PART NO. CODE
19B555 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks
Onto Passenger Front Floor
Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Front
Floor
TSB 05-20-7
10/17/05
A/C CONDENSATION LEAKING ONTO THE PASSENGER FRONT FLOOR
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
ISSUE Some 2005-2006 Expedition and Navigator vehicles may exhibit water leaking on to the
passenger floor from the NC plenum drain tube area.
ACTION Refer to the following Service Procedure to determine if the water leak is from the air
conditioning drain tube and repair as necessary.
SERVICE PROCEDURE
1. Turn off air suspension, if equipped.
2. Verify the leak is from the HVAC case drain seal and not from another source. Pull back the
carpet on the passenger floorboard and feel the HVAC drain tube seal for water (Figure 1A-1B).
a. If signs of water or moisture are present continue on with the TSB.
b. If there are no signs of water or moisture at the drain tube seal, follow normal diagnosis and
repair procedures.
3. Expedition only: Open hood and remove transmission dip stick.
4. Navigator only: Use Message Center to position running boards in the extended position (out
setting). Refer to Owners Guide, drivers control
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks
Onto Passenger Front Floor > Page 7702
section for more information.
5. Remove the right front wheel following Workshop Manual, Section 204-04 procedure.
6. Remove right front fender splash shield.
7. Expedition only: Remove transmission dipstick tube from vehicle.
8. Pull back the engine compartment dash panel insulator far enough to expose the HVAC drain
tube (Figure 2B) by removing the push pin to the right of the drain (Figure 2A).
9. Push elbow (P/N F3LY-6A614-A) onto drain tube to install. Make sure the short end of the elbow
is pushed onto the drain tube, and the long end is pointed straight down (Figure 3). Only water may
be used to aid in pushing the elbow onto the drain tube. (Do not use soap or petroleum products on
the elbow).
10. Re-seat the engine compartment dash panel insulator and replace the push pin.
11. Expedition only: Install transmission dipstick and tube.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks
Onto Passenger Front Floor > Page 7703
12. Verify the repair by ensuring condensation is dripping outside the vehicle and not running inside
onto the passenger floorboard.
13. Replace the right front fender splash shield and wheel.
14. Turn air suspension back on, if equipped.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052007A 2005-2006 Expedition: 0.9 Hr
Install Extension On Evaporator Drain (Do not use with 7228A)
052007B 2005-2006 Navigator: 0.7 Hr
Install Extension On Evaporator Drain (Do not use with 7228A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19B739 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-8-7 > May > 05 > A/C - Water Leaks
Onto Passenger Compartment Floor
Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Onto Passenger
Compartment Floor
TSB 05-8-7
05/02/05
WATER LEAK INTO PASSENGER COMPARTMENT FLOOR AND/OR RATTLE NOISE FROM
DASH
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built 8/01/2004 through 1/17/2005, may exhibit a
water (condensation) leak into the passenger compartment floor and/or a rattle noise coming from
the dash. This may be due to the evaporator case lower stud and nut being loose allowing water to
seep past the seal between the evaporator case and the drain tube.
ACTION
Tighten the nut that attaches the evaporator case to the stud to 42 lb-in (4.8 N.m) (Figure 1).
Ensure that the case is tight to the drain tube seal. The case stud and nut can be accessed from
under the dash by pulling the carpet back on the passenger side floor.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050807A 2005 Expedition/Navigator 0.2 Hr.
Tighten The Lower Evaporator Case Stud
DEALER CODING
CONDITION
BASIC PART NO. CODE
19B555 33
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart (Part 1)
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart (Part 2)
The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a
thermistor device in which resistance changes with temperature. The electrical resistance of a
thermistor decreases as the temperature increases, and the resistance increases as the
temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN
also connected to the ACET sensor, the varying resistance affects the voltage drop across the
sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET
sensor changes the voltage the PCM detects.
The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost (demist
performance, reduce A/C clutch cycling, etc.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Description and Operation > Page 7711
Evaporator Temperature Sensor / Switch: Service and Repair
AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR
Removal and Installation
1. Lower the glove compartment.
2. Remove the screw and disconnect the evaporator discharge air temperature sensor electrical
connector.
3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and
evaporator core housing. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Customer Interest for Expansion Valve: > 06-10-4 > May > 06 > A/C - Rear A/C Hoot/Whistle Noise
Expansion Valve: Customer Interest A/C - Rear A/C Hoot/Whistle Noise
TSB 06-10-4
05/29/06
HOOT OR WHISTLE NOISE FROM REAR A/C SYSTEM
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-21-1 to add a production fix date.
ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 1/30/2006 may exhibit a hoot or
whistle noise inside the passenger compartment, coming from the rear auxiliary A/C system. The
noise will most likely be heard by the customer when driving the vehicle with the interior cooled
down, the rear A/C off, front A/C on, and the blower fan on the low speed setting.
ACTION Replace the thermostatic expansion valve (TXV), located near the rear auxiliary A/C
housing, following the Workshop Manual procedure (Removal And Installation: Thermostatic
Expansion Valve). The procedure can be found in Section 412-03B of the 2005 MY Workshop
Manual, or Section 412-02 of the 2006 MY Workshop Manual.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061004A 2005-2006 1.7
Expedition/Navigator: Hrs.
Replace The Thermostatic Expansion Valve Includes Time To Verify Concern, Recover, Evacuate,
Re- Charge Air Conditioning System: (Do not use with 19700A, 19700AZU, 19700A13)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Expansion Valve: > 06-10-4 > May > 06 > A/C - Rear A/C Hoot/Whistle Noise
Expansion Valve: All Technical Service Bulletins A/C - Rear A/C Hoot/Whistle Noise
TSB 06-10-4
05/29/06
HOOT OR WHISTLE NOISE FROM REAR A/C SYSTEM
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-21-1 to add a production fix date.
ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 1/30/2006 may exhibit a hoot or
whistle noise inside the passenger compartment, coming from the rear auxiliary A/C system. The
noise will most likely be heard by the customer when driving the vehicle with the interior cooled
down, the rear A/C off, front A/C on, and the blower fan on the low speed setting.
ACTION Replace the thermostatic expansion valve (TXV), located near the rear auxiliary A/C
housing, following the Workshop Manual procedure (Removal And Installation: Thermostatic
Expansion Valve). The procedure can be found in Section 412-03B of the 2005 MY Workshop
Manual, or Section 412-02 of the 2006 MY Workshop Manual.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061004A 2005-2006 1.7
Expedition/Navigator: Hrs.
Replace The Thermostatic Expansion Valve Includes Time To Verify Concern, Recover, Evacuate,
Re- Charge Air Conditioning System: (Do not use with 19700A, 19700AZU, 19700A13)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair
> Thermostatic Expansion Valve
Expansion Valve: Service and Repair Thermostatic Expansion Valve
Air Conditioning
THERMOSTATIC EXPANSION VALVE
Removal and Installation
NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of system contamination from a failed A/C compressor or
damage to the receiver/drier.
1. Recover the refrigerant. 2. Disconnect the negative battery cable.
3. Disconnect the powertrain control module (PCM) electrical connectors.
4. Remove the bolts and the PCM.
5. Remove the bolts and the PCM bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair
> Thermostatic Expansion Valve > Page 7727
6. Remove the thermostatic expansion valve fitting bolt.
- Discard the O-ring seals.
7. Remove the bolts and the thermostatic expansion valve.
- Discard the O-ring seals.
8. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
9. Evacuate, leak test and charge the refrigerant system.
Auxiliary Climate Control
THERMOSTATIC EXPANSION VALVE
Removal and Installation
1. Recover the refrigerant. 2. Remove the RH quarter trim panel.
3. Disconnect the fittings and remove the thermostatic expansion valve.
- Discard the O-ring seals.
4. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
5. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair
> Thermostatic Expansion Valve > Page 7728
Expansion Valve: Service and Repair Thermostatic Expansion Valve Manifold and Tube Assembly
THERMOSTATIC EXPANSION VALVE MANIFOLD AND TUBE ASSEMBLY
Removal and Installation
NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
1. Recover the refrigerant.
2. Remove the nut and disconnect the A/C fitting.
- Discard the O-ring seal.
3. Remove the nut and disconnect the A/C fitting.
- Discard the O-ring seal.
4. Remove the bolt and the thermostatic expansion valve manifold and tube assembly. 5. To install,
reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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
7737
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 5 (2005))
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
7738
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 5 (2005))
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 5 (2005))
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 7744
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 5 (2005))
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 7745
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7746
Heater Core: Description and Operation
HEATER CORE
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer the heat to air passing through the plenum.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7747
Heater Core: Testing and Inspection
HEATER CORE
WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate
the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to
vent the exhaust gases outside the closed area.
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were
good and did not require replacement. If a heater
core leak is suspected, the heater core must be tested by carrying out the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking
the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core - Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is working
correctly.
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose
to see if it is hot.
If it is not hot: -
the heater core may have an air pocket.
- the heater core may be plugged.
- the thermostat is not working correctly.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter
BT-7422-A from the Radiator/Heater Core
Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of 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 perform the bench test.
Heater Core - Bench Test
1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3.
Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes.
Then connect the Radiator/Heater Core Pressure
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7748
Tester to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heating and Ventilation
Heater Core: Service and Repair Heating and Ventilation
HEATER CORE
REMOVAL
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
1. Remove the plenum chamber.
2. Remove the dash panel seal.
3. Remove the screws and the heater core cover. 4. Remove the heater core.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heating and Ventilation > Page 7751
Heater Core: Service and Repair Auxiliary Climate Control
HEATER CORE
Removal and Installation
1. Remove the auxiliary climate control housing.
2. Remove the screws and the evaporator/heater core access cover.
3. Remove the heater core. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest: > 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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7760
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7761
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7767
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7768
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349
Alternator: All Technical Service Bulletins Charging System - DTC P0340/P0344/P0345/P0349
TSB 06-19-12
10/02/06
DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V
FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer
2007 Explorer Sport Trac
LINCOLN: 2005-2006 Navigator
MERCURY: 2006 Mountaineer
This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and
service parts updated.
ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005
and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT
vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or
P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a
4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning
diode or open phase connection in the generator.
ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the
generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for
performing a generator frequency test using the WDS oscilloscope function.
SERVICE PROCEDURE
NOTE
USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD
INDICATOR OF A FAULTY GENERATOR.
NOTE
ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE.
1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean
and secure.
2. Attach WDS battery cable clamps to battery/battery cables.
3. Turn on WDS.
4. Select the Toolbox Icon, (upper left of WDS screen).
5. Select Oscilloscope and then click OK.
6. Select Channel 1, Auto, Generator Ripple.
7. Select Calculations, Channel 1, Frequency.
8. Select Calculations again.
9. Push the RUN/STOP button. A waveform should display on the screen.
10. Start the vehicle and leave at idle (engine speed less than 800 RPM).
11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc).
12. Examine the frequency reading on WDS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7774
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7775
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7776
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7777
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7783
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7784
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7785
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 7786
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling
Heater Hose: Service and Repair Heater Hose Coupling
HEATER HOSE COUPLING
Remover, Heater Hose Inlet Tube
Special Tool(s)
Disconnect
1. WARNING: The engine must be off, fully cool and the cooling system fully depressurized before
attempting to disconnect any heater
water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid
escaping out of the engine cooling system.
Depressurize the engine cooling system.
2. Push the heater water hose toward the tube to fully expose the locking tabs.
3. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must
be perpendicular to and on the highest point of the
coupling.
Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to
assist in the removal.
Pull the heater water hose away from the heater core tube.
5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling > Page 7789
7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer.
Connect
1. Clean the tubes and lubricate with MERPOL(R) meeting Ford specification ESE-M99B144-B or
plain water.
2. Install a new coupling retainer, spacer, and lubricated O-ring seals into the quick disconnect
coupling housing.
3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the
coupling is fully engaged by lightly pulling on the heater water hose.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling > Page 7790
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE
Removal
CAUTION: To avoid refrigerant loss, clearly differentiate the auxiliary heater lines from the auxiliary
refrigerant lines before beginning this procedure.
NOTE:
- The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary
heater inlet line and outlet line are each installed from the factory as one piece assemblies. The
replacement parts are supplied as separate kits containing multiple piece lines for ease of
installation.
- The following procedure can be used to remove and install one of, or both the auxiliary heater
inlet line and auxiliary heater outlet line. If only one auxiliary heater line is to be removed and
installed, cut or disconnect only the desired line at the specified points within the procedure.
1. Drain the engine coolant. 2. Remove the RH quarter trim panel.
3. Detach the auxiliary heater lines.
1 Disconnect the heater hose(s).
2 Remove the bolts.
3 Remove the line bracket.
4. Remove the spare tire. 5. Raise the vehicle. 6. Remove the RH front wheel. 7. Remove the RH
fender splash shield.
8. NOTE: If installing only one auxiliary heater line, disconnect only the desired line.
Disconnect the heater hose(s).
9. Remove the muffler.
10. Remove the RH catalytic converter.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling > Page 7791
11. Remove the three bolts and the heat shield.
12. Remove the bolts.
13. Remove the nut and the line bracket.
14. Remove the bolt and the heat shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling > Page 7792
15. Remove the nuts and the remaining line brackets.
16. NOTE: If installing only one auxiliary heater line, cut only the desired line.
Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using
a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s).
17. Remove the auxiliary heater line(s) in three separate pieces.
Installation
1. Partially lower the vehicle.
2. Attach the rear portion of the auxiliary heater lines.
1 Connect the heater hoses.
2 Install the line bracket.
3 Install the bolts.
3. Install the front auxiliary heater line(s) and connect the heater hose(s).
- Clean and lubricate the heater hoses with plain water only if needed.
4. Raise the vehicle.
5. NOTE: Loosely connect, but do not tighten, the fittings.
Install the middle auxiliary heater line(s).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling > Page 7793
6. Starting from the rear of the vehicle, install the first three line brackets. 7. Tighten the middle
auxiliary heater line fittings. 8. Inspect the auxiliary heater lines for correct installation. Loosen,
reposition and tighten as needed.
9. Install the heat shield and the bolts.
10. Install the heat shield and the bolts. 11. Install the RH catalytic converter. 12. Install the muffler.
13. Partially lower the vehicle.
14. Install the heat shield bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hose Coupling > Page 7794
15. Install the line bracket. 16. Lower the vehicle. 17. Install the spare tire. 18. Install the RH
quarter trim panel. 19. Fill the engine coolant level.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
Hose/Line HVAC: Service and Repair
COMPRESSOR MANIFOLD AND TUBE ASSEMBLY
Removal and Installation
NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
All vehicles 1. Recover the refrigerant. 2. Disconnect the negative and positive battery cable.
3. Disconnect the electrical connector.
4. Disconnect the pressure cutoff switch electrical connector.
5. Remove the nut and disconnect the A/C fitting.
- Discard the O-ring seal.
Vehicles with auxiliary A/C
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Page 7798
6. Remove the nut and disconnect the auxiliary A/C line fitting.
- Discard the O-ring seal.
All vehicles
7. Remove the nut and disconnect the A/C fitting.
- Discard the O-ring seal.
8. Loosen the bolt and remove the compressor manifold and tube assembly.
- Discard the O-ring seals.
9. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
10. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Description and Operation
Housing Assembly HVAC: Description and Operation
PLENUM CHAMBER
The plenum chamber directs airflow from the blower motor through the evaporator core and heater
core. All airflow from the blower motor passes through the evaporator core. Airflow is then directed
through or around the heater core by the temperature blend door(s). Vehicles equipped with DATC
use a partitioned plenum chamber with two electric actuator-positioned temperature blend doors.
This allows for separate temperatures to be selected for the driver and passenger sides of the
passenger compartment. Manual systems use a single electric actuator-positioned temperature
blend door to direct airflow through or around the heater core.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Description and Operation > Page 7802
Housing Assembly HVAC: Service and Repair
PLENUM CHAMBER
Removal and Installation
NOTE:
- If an evaporator core leak is suspected, the evaporator must be vacuum leak tested before it is
removed from the vehicle.
- Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. Refer to:
Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair,
Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Installation
4. Remove the rear footwell duct.
5. Disconnect the powertrain control module (PCM) electrical connectors.
6. Remove the bolts and remove the PCM.
7. Remove the bolts and remove the PCM bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Description and Operation > Page 7803
8. Disconnect the quick-disconnect fittings at the heater core.
9. Disconnect the fittings at the thermostatic expansion valve.
- Discard the O-ring seals.
10. Disconnect the A/C fittings at the evaporator core.
- Discard the O-ring seals.
11. Remove the nut.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Description and Operation > Page 7804
12. Remove the nut.
13. Remove the nut.
14. Disconnect the two vacuum lines at the top of the plenum chamber.
15. Remove the screws and position the wire harness aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Description and Operation > Page 7805
16. Remove the nuts.
17. Remove the nut.
18. Remove the nut and remove the plenum chamber. 19. To install, reverse the removal
procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
- Clean and lubricate the coolant hoses with plain water only if needed.
20. Refill the engine coolant level. 21. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Diagrams > Page
7809
Humidity Sensor: Service and Repair
IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR
Removal and Installation
1. Remove the in-vehicle temperature and humidity sensor trim cover.
2. Disconnect the aspirator hose and the in-vehicle temperature and humidity sensor electrical
connector.
3. Remove the screws and the in-vehicle temperature and humidity sensor. 4. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair
Receiver Dryer: Service and Repair
RECEIVER DRIER
Removal and Installation
NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the receiver/drier.
All vehicles 1. Recover the refrigerant.
2. Disconnect the A/C fitting.
- Discard the O-ring seal.
Vehicles without auxiliary A/C
3. Disconnect the A/C fitting.
- Discard the O-ring seal.
Vehicles with auxiliary A/C
4. Remove the nuts and disconnect the A/C fittings.
- Discard the O-ring seal.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair >
Page 7813
5. Remove the nut, detach the bracket and remove the receiver/drier. 6. To install, reverse the
removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
7. Evacuate, leak test and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Customer Interest for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor Cooling
Performance
Refrigerant: Customer Interest A/C - Hooting/Whistling Noise/Poor Cooling Performance
TSB 05-4-11
03/07/05
NOISE FROM A/C OR INSUFFICIENT A/C COOLING
FORD: 2004-2005 Expedition
LINCOLN: 2004-2005 Navigator
ISSUE Some 2004-2005 Expedition/Navigator vehicles built between 04/01/2004 and 9/26/2004,
may exhibit a hoot or whistle noise inside the passenger compartment, coming from the A/C
system. The vehicle may also exhibit insufficient A/C cooling. This may be due to low A/C
refrigerant charge from the factory.
ACTION If normal diagnostics do not point to a system leak, evacuate and recharge the A/C
system. Charge the system to 40 ounces for systems that are not equipped with rear A/C, and 58
ounces for vehicles that are equipped with rear A/C. Refer to Workshop Manual Section 412-00
A/C system leak diagnostics and system recovery, evacuation and recharging.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050411A 2004-2005 Expedition 0.6 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles Without Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
050411B 2004-2005 Expedition 0.8 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles With Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Customer Interest for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor Cooling
Performance > Page 7822
DEALER CODING
CONDITION
BASIC PART NO. CODE
FREON 51
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor
Cooling Performance
Refrigerant: All Technical Service Bulletins A/C - Hooting/Whistling Noise/Poor Cooling
Performance
TSB 05-4-11
03/07/05
NOISE FROM A/C OR INSUFFICIENT A/C COOLING
FORD: 2004-2005 Expedition
LINCOLN: 2004-2005 Navigator
ISSUE Some 2004-2005 Expedition/Navigator vehicles built between 04/01/2004 and 9/26/2004,
may exhibit a hoot or whistle noise inside the passenger compartment, coming from the A/C
system. The vehicle may also exhibit insufficient A/C cooling. This may be due to low A/C
refrigerant charge from the factory.
ACTION If normal diagnostics do not point to a system leak, evacuate and recharge the A/C
system. Charge the system to 40 ounces for systems that are not equipped with rear A/C, and 58
ounces for vehicles that are equipped with rear A/C. Refer to Workshop Manual Section 412-00
A/C system leak diagnostics and system recovery, evacuation and recharging.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050411A 2004-2005 Expedition 0.6 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles Without Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
050411B 2004-2005 Expedition 0.8 Hr.
Navigator: Pressurize, Leak Test, Discharge, Evacuate And Charge Air Conditioning System. Diagnosis Includes Time To Partially Charge The System, Test For Leaks. Also Includes Time To
Recover, Recharge System Requires Use Of A Rotunda Approved R-134a Refrigerant
Recovery/Recycling/Charging Station. Vehicles With Rear A/C (Do Not Use With 19700A,
19700AZU, 19700C, 6007AXA)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Refrigerant: > 05-4-11 > Mar > 05 > A/C - Hooting/Whistling Noise/Poor
Cooling Performance > Page 7828
DEALER CODING
CONDITION
BASIC PART NO. CODE
FREON 51
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant Capacity
Without Auxiliary Climate Control ........................................................................................................
.........................................................40 oz (1.13 kg)
With Auxiliary Climate Control .............................................................................................................
.........................................................58 oz (1.64 kg)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 7831
Refrigerant: Fluid Type Specifications
Refrigerant Fluid ..................................................................................................................................
.......................................................................R-134a
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection
Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection
FLUORESCENT DYE LEAK DETECTION
Special Tool(s)
Special Tool(s)
Fluorescent Dye Detection
NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the
refrigerant system from the factory. The location of leaks can be pinpointed by the bright
yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist,
make sure to inspect each component, line, and fitting in the refrigerant system for a leak.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 7834
1. Check for leaks using a Rotunda approved UV lamp.
- Inspect all components, lines and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate
and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of
fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the
leak with a Rotunda-approved UV lamp.
Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
NOTE:
- Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the
desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is
not necessary to add dye after flushing or filtering the refrigerant system because a new suction
accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant
capacity has been lost due to a fitting separation, hose rupture or other damage.
- Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers
instructions on evacuation of any non-condensable gasses from the hoses.
- Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service
center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way
check valve that will prevent refrigerant system recovery and evacuation.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant
system service port valves.
2. Verify that the valves on the fluorescent dye injector are closed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 7835
3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the
fluorescent dye injector between the low-pressure service gauge port valve and the R-134a
refrigerant service center or manifold gauge
set.
5. Open all valves and inject the fluorescent dye into the refrigerant system. 6. When fluorescent
dye injection is complete, close all valves. 7. Recover the refrigerant from the R-134a fluorescent
dye injector. 8. Remove the fluorescent dye injector from the low-pressure service gauge port valve
and the R-134a A/C refrigerant service center or manifold
gauge set.
Fluorescent Dye Injection - Using a Dye Injector Loop Kit
NOTE:
- Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the
desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is
not necessary to add dye after flushing or filtering the refrigerant system because a new suction
accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant
capacity has been lost due to a fitting separation, hose rupture or other damage.
- Before using the R-134a fluorescent dye injector for the first time, refer to the equipment
manufacturers instructions on evacuation of non-condensable gasses from the hoses.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C.
1. Verify that the valves on the deluxe injector loop kit are closed.
2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye. 3. Install the
deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 7836
4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt
before starting the engine.
Start the engine.
5. Open the high-pressure service valve.
6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to
equalize with the suction side of the refrigerant
system.
8. NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating.
Close the valves on the deluxe injector loop kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 7837
9. NOTE: Leave all valves on the special tool closed when not in use.
Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop
kit from the vehicle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Fluorescent Dye Leak Detection > Page 7838
Refrigerant: Testing and Inspection Electronic Leak Detection
ELECTRONIC LEAK DETECTION
H10PM Refrigerant Leak Detector With Battery
Special Tool(s)
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate
this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner,
or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be
tested before proceeding with the leak detection procedure is helpful in removing small traces of
contamination from the air, but the fan should be turned off during actual testing.
1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, recover the refrigerant.
- Repair the system.
- Test the system for normal operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure
Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure
AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING
Special Tool(s)
Special Tool(s)
Refrigerant System Recovery
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that
may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to
leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify
that no leaks are present.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7841
1. Prior to recovering, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant
service center to the low- and high-pressure service gauge port valves following the operating
instructions provided
by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. 4. Once the refrigerant service center has recovered the refrigerant,
switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the
system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the
system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for two
minutes. 7. Carry out the required repairs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7842
Refrigerant: Service and Repair Evacuation and Charging
AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING
Special Tool(s)
Special Tool(s)
Refrigerant System Evacuation Using an R-134a Service Center
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that
may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to
leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify
that no leaks are present.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7843
1. Connect an R-134a service center to the low- and high-pressure service gauge port valves
following the operating instructions provided by the
equipment manufacturer.
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of
vacuum and as close to 101.1 kPa (30 in-Hg) as
possible. Continue to operate the vacuum pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low-pressure gauge for 5 minutes to make sure that the
system vacuum is held. If vacuum is not held for 5
minutes, leak test the system, repair the leak and evacuate the system again.
Refrigerant System Evacuation Using an R-134a Manifold Gauge Set
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that
may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to
leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify
that no leaks are present.
1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves.
2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum
pump. 3. Open all valves on the R-134a manifold gauge set and both service gauge port valves. 4.
Turn on the vacuum pump and evacuate the system until the low-pressure gauge reads at least
99.4 kPa (29.5 in-Hg) of vacuum and as close to
101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45
minutes.
5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port
valves) and turn off the vacuum pump. 6. Observe the low-pressure gauge for 5 minutes to make
sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the
system, repair the leak and evacuate the system again.
Refrigerant System Charging Using an R-134a Service Center
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be
misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Connect an R-134a
A/C service center to the low-side and high-side service gauge port valves following the operating
instructions provided by the
equipment manufacturer.
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions
provided by the equipment manufacturer.
Refrigerant System Charging
NOTE:
- Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging meter, and manifold gauge set.
- Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be
misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all
refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks
are present.
1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Assemble the
R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following
the automatic refrigerant
charging meter operating instructions.
3. Charge the refrigerant system following the automatic refrigerant charging meter operating
instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the
engine, select A/C operation and allow the refrigerant charge to
complete.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7844
Refrigerant: Service and Repair Refrigerant Identification Testing
REFRIGERANT IDENTIFICATION TESTING
Refrigerant Identifier With Air-Radicator
Special Tool(s)
Refrigerant Identification
1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior
to recovering or charging the refrigerant system.
Follow the instructions included with the refrigerant identifier to obtain the sample for testing.
2. The diagnostic tool will display one of the following:
- If the purity level of R-134a is 98% or greater by weight, the green "PASS" light emitting diode
(LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be
displayed on the digital display.
- If refrigerant R-134a does not meet the 98% purity level, the red "FAIL" LED will light and an
alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12,
R-22, and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the
user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will
also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The diagnostic tool eliminates the effect of
air when determining the refrigerant sample content because air is not considered a contaminant,
although air can affect A/C system performance. When the diagnostic tool has determined that a
refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2%
or greater by weight, the diagnostic tool will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7845
Refrigerant: Service and Repair Contaminated Refrigerant Handling
CONTAMINATED REFRIGERANT HANDLING
CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the air
conditioning system flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
- If this equipment is not available, contact an A/C service facility in your area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern. 3. Flush the air conditioning
system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local
regulations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Refrigerant Oil Capacity
Without Auxiliary Climate Control ........................................................................................................
............................................................9 oz (266 ml)
With Auxiliary Climate Control .............................................................................................................
..........................................................14 oz (414 ml)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7850
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil Type.............................................................................................................................
.......................................PAG Motorcraft YN-12-C
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
7851
Refrigerant Oil: Service and Repair
REFRIGERANT OIL ADDING
Special Tool(s)
Special Tool(s)
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart for refrigerant oil adding amounts and methods of installation.
Refrigerant Oil Adding for New A/C Compressor Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
7852
NOTE: Service A/C compressors are shipped without refrigerant oil.
1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the
refrigerant oil in a clean measuring cup.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), add
the same amount plus the amount collected during refrigerant recovery.
- If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 ounces), add
the same amount plus the amount collected during refrigerant recovery.
- If the amount of oil drained from the old A/C compressor is less than 85 ml (3 ounces), add 85 ml
(3 ounces) plus the amount collected during refrigerant recovery.
Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation
1. Drill one half-inch hole in the old suction accumulator or receiver/drier cylinder and drain the oil
into a clean measuring cup. 2. Add the quantity of oil drained, plus the amount collected during
refrigerant recovery and 60 ml (2 ounces).
Oil Injection Using a Dye/Lubricant Injector
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be
added to the dye/lubricant injector along with the refrigerant oil.
1. Evacuate the refrigerant system. 2. Assemble the dye/lubricant injector using the correct
adapters to match the amount of PAG oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean PAG oil. 5. Install the dye/lubricant
injector between the low-side service gauge port valve and the refrigerant service station or
manifold gauge set. 6. Open all valves and charge the refrigerant system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7857
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7861
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Front Blower Motor Relay
Blower Motor Relay: Locations Front Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Front Blower Motor Relay > Page 7867
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Front Blower Motor Relay > Page 7868
Blower Motor Relay: Locations Rear Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Front Blower Motor Relay > Page 7869
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Front Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Front Blower Motor Relay > Page 7872
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Front Blower Motor Relay
Blower Motor Relay: Testing and Inspection Front Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Front Blower Motor Relay > Page 7875
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Front Blower Motor Relay > Page 7876
Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Front Blower Motor Relay > Page 7877
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7881
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7882
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7883
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING CLUTCH RELAY (A/CCR)
NOTE: The PCM PIDs WAC and WACF are used to monitor the A/CCR output.
The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally
open. There is no direct electrical connection between the A/C switch or EATC module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the communications network). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as 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 A/CCR output, closing the relay contacts and sending
voltage to the A/C clutch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7884
Compressor Clutch Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7885
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 7889
Control Module HVAC: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 7890
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7895
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7896
Ambient Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7897
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
Removal and Installation
Expedition
1. Remove the radiator sight shield.
1 Remove the pin-type retainers.
2 Remove the radiator sight shield.
All vehicles
2. Detach the ambient temperature sensor pin-type retainer.
3. Disconnect the electrical connector and remove the ambient temperature sensor. 4. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Service and Repair > Blower Motor Switch
Blower Motor Switch: Service and Repair Blower Motor Switch
BLOWER MOTOR SWITCH
Removal and Installation
1. Remove the climate control assembly. 2. Pull and remove the blower motor switch knob.
3. Release the clips and remove the blower motor switch. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Service and Repair > Blower Motor Switch > Page 7902
Blower Motor Switch: Service and Repair Blower Motor Speed Control
BLOWER MOTOR SPEED CONTROL
Removal and Installation
1. Remove the RH lower instrument panel insulator.
2. Remove the blower motor speed control.
1 Remove the screw.
2 Remove the blower motor speed control.
3 Disconnect the blower motor speed control electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 7908
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Diagrams > Page 7909
In-Vehicle Temperature Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor
IN-VEHICLE TEMPERATURE SENSOR
Removal and Installation
1. Remove the screws and the instrument cluster finish panel.
- Disconnect the electrical connectors.
2. Disconnect the aspirator hose and the in-vehicle temperature sensor electrical connector.
3. Remove the screws and the in-vehicle temperature sensor. 4. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor > Page 7912
Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity
Sensor
IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR
Removal and Installation
1. Remove the in-vehicle temperature and humidity sensor trim cover.
2. Disconnect the aspirator hose and the in-vehicle temperature and humidity sensor electrical
connector.
3. Remove the screws and the in-vehicle temperature and humidity sensor. 4. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart (Part 1)
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart (Part 2)
The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a
thermistor device in which resistance changes with temperature. The electrical resistance of a
thermistor decreases as the temperature increases, and the resistance increases as the
temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN
also connected to the ACET sensor, the varying resistance affects the voltage drop across the
sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET
sensor changes the voltage the PCM detects.
The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost (demist
performance, reduce A/C clutch cycling, etc.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Description and Operation > Page 7916
Evaporator Temperature Sensor / Switch: Service and Repair
AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR
Removal and Installation
1. Lower the glove compartment.
2. Remove the screw and disconnect the evaporator discharge air temperature sensor electrical
connector.
3. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and
evaporator core housing. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component
Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component
Information > Diagrams > Page 7920
Humidity Sensor: Service and Repair
IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR
Removal and Installation
1. Remove the in-vehicle temperature and humidity sensor trim cover.
2. Disconnect the aspirator hose and the in-vehicle temperature and humidity sensor electrical
connector.
3. Remove the screws and the in-vehicle temperature and humidity sensor. 4. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7925
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7929
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 7933
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Service Port HVAC: Locations
Clutch Cycling Thermostatic Expansion Valve Type Refrigerant System
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page
7937
Index For Diagram
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 7941
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and
Repair
Vacuum Harness HVAC: Service and Repair
VACUUM HOSE REPAIR - MINI-TUBE
Vacuum Pump Kit
Special Tool(s)
1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of
standard 1/8-inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the
damaged area of the mini-tube
vacuum hose.
3. Cut off the mini-tube vacuum hose on each side of the damaged area.
4. WARNING: Read the warning information on the product label to prevent possible personal
injury.
Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone
(MEK). This solvent will seal the mini-tube in the vacuum hose.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the
standard 1/8-inch repair vacuum hose section. 6. Shake the repair joint after assembly to make
sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum
leak in the repair area.
- Use the Vacuum Pump or equivalent.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service
and Repair
Vacuum Reservoir HVAC: Service and Repair
VACUUM RESERVOIR
Removal and Installation
1. Remove the battery and battery tray.
2. Disconnect the vacuum hose and remove the vacuum reservoir. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations > Page 7951
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations > Page 7952
ATC Solenoid And Manifold
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations > Page 7953
Vacuum Solenoid Valve HVAC: Service and Repair
AUTOMATIC TEMPERATURE CONTROL SOLENOID AND MANIFOLD
Removal and Installation
Navigator
1. Remove the floor console trim panel.
Expedition
2. Remove the bolts and the instrument panel brace.
All vehicles
3. Remove the automatic temperature control (ATC) solenoid and manifold.
1 Disconnect the vacuum and electrical connectors.
2 Remove the screw.
3 Remove the ATC solenoid and manifold.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 7959
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 5 (2005))
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 7960
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
SAFETY BELT PROCEDURE AFTER A COLLISION
1. WARNING: All safety belt assemblies including retractors, 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. See:
Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7966
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7967
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7968
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7969
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7970
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7971
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7972
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7973
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7974
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7975
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7976
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7977
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 7978
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams >
Passenger Air Bag Module
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams >
Passenger Air Bag Module > Page 7984
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams >
Passenger Air Bag Module > Page 7985
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page
7986
Air Bag: Description and Operation
Driver Air Bag Module
The driver air bag module: is installed new as an assembly.
- is mounted in the center of the steering wheel.
- cannot be interchanged between Expedition and Navigator vehicles.
Passenger Air Bag Module
The passenger air bag module: is installed new as an assembly.
- is mounted in the passenger side of the instrument panel.
- cannot be interchanged between Expedition and Navigator vehicles.
Safety Canopy Module
Some vehicles can be equipped with optional safety canopies for protection during side impacts or
rollovers.
Vehicles equipped with safety canopies require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopies, make sure a headliner for safety canopies is
being used. The word "AIRBAG" will appear on the headliner where it meets each B-pillar trim
panel.
The safety canopy module: is installed as an assembly.
- is mounted above the headliner.
- attaches from the A-pillar frame to the C-pillar frame.
- is standard equipment on the Navigator and optional on the Expedition.
- cannot be interchanged from side to side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module
Air Bag: Service and Repair Driver Air Bag Module
DRIVER AIR BAG MODULE
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
- Restraint system diagnostic tools are for service only. Tools must be removed prior to operating
the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury
and possible violation of vehicle safety standards.
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.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles 1. Depower the system.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7989
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
5. Disconnect the driver air bag module
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
6. Release the tab and disconnect the driver air bag module accessories electrical connector at the
top of the clockspring and remove the driver air
bag module.
Installation
Navigator vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7990
1. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
2. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
3. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7991
4. Install the two driver air bag module bolts (one shown).
5. Install the two steering wheel back cover plugs (one shown). 6. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7992
Air Bag: Service and Repair Passenger Air Bag Module
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 trim covers must be replaced, not repainted.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles 1. Depower the system.
2. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
3. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7993
4. Through the glove box opening, remove the passenger air bag module bolts.
Navigator vehicles
5. Through the glove box opening, remove the passenger air bag module nuts.
All vehicles
6. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
NOTE: The Expedition is shown, the Navigator is similar.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
remove the passenger air bag module from the instrument panel.
Installation
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7994
1. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
NOTE: The Expedition is shown, the Navigator is similar.
Position the passenger air bag module into the instrument panel.
Navigator vehicles
2. Install the passenger air bag module nuts.
Expedition vehicles
3. Install the passenger air bag module bolts.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7995
4. NOTE: Expedition is shown, Navigator is similar.
Connect the passenger air bag module electrical connector.
5. Close the glove box. 6. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7996
Air Bag: Service and Repair Safety Canopy Module
SAFETY CANOPY 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.
- To reduce the risk of personal injury from an accidental deployment, always carry or place a live
safety canopy module with the safety canopy and tear seam pointed away from your body. Failure
to do so can result in personal injury in the event of a safety canopy module deployment.
- After deployment, the surface of the safety canopy can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
- Never probe the connector on the safety canopy module. Doing so can result in safety canopy
deployment which can result in personal injury.
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment.
- Vehicles equipped with safety canopy modules require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety
canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets
each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety
canopy module deployment.
- Before installing the safety canopy module, inspect the roofline for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be replaced and any foreign objects removed. Failure to do so may result in
personal injury in the event of a safety canopy deployment.
- Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has
separated or safety canopy material has been exposed, a new safety canopy module must be
installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can
result in personal injury in the event of a safety canopy module deployment.
- To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety
canopy module. Failure to follow these instructions can result in personal injury in the event of a
safety canopy module deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
- The passenger side safety canopy module is shown, the driver side is similar.
All vehicles 1. Depower the system.
2. WARNING:
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
- Vehicles equipped with safety canopy modules require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety
canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets
each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety
canopy module deployment.
Remove the headliner.
Vehicles with a moonroof
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7997
3. Separate the moonroof drain tube and position to the side.
All vehicles
4. CAUTION: Inspect the rivet nut and A-pillar sheet metal for damage. Install a new rivet nut if
necessary.
Remove the tether cord bolt and bracket from the A-pillar.
5. NOTE: If not installing a new safety canopy module, the pin-type retainer can remain installed.
Remove the tether cord and pin-type retainer from the A-pillar.
6. Remove the screw at the roofline near the A-pillar.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7998
7. Separate the rear tether bracket assembly from the C-pillar.
1 Remove the bolts.
2 Slide up and rotate the hook out, separating the tether bracket assembly from the C-pillar.
8. Remove the safety canopy wire harness and electrical connector pin-type retainers at the
C-pillar.
9. Remove the screw at the rear ramp.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7999
10. Remove the screws at the canister.
11. Remove the two screws at the front ramp.
12. Slide the front of the safety canopy up and rotate the hook out of the roofline sheet metal and
remove the safety canopy.
Installation
All vehicles
1. WARNING:
- Before installing the safety canopy module, inspect the roofline for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be replaced and any foreign objects removed. Failure to do so may result in
personal injury in the event of a safety canopy module deployment.
- Before installing the safety canopy module, if the module is damaged or the cover has separated
or the safety canopy material has
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8000
been exposed, install a new safety canopy module. Do not attempt to repair the safety canopy.
Failure to follow these instructions could result in personal injury in the event of a safety canopy
deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
With the safety canopy module positioned in the vehicle as shown, angle the rear of the safety
canopy module to the sheet metal, so that the deployment canister can be inserted into the sheet
metal opening.
2. Position the safety canopy and engage the front hook to the roofline sheet metal.
3. Install the screw at the roofline near the A-pillar.
4. Install the two screws at the front ramp.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8001
5. Install the screw at the rear ramp.
6. Install the screws at the canister.
7. Route and install the safety canopy wire harness and electrical connector pin-type retainers at
the C-pillar.
8. Install the rear tether bracket assembly to the C-pillar.
1 Rotate and slide down the tether bracket assembly hook, engaging it to the C-pillar sheet metal.
2 Install the bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8002
9. CAUTION: Inspect the rivet nut and A-pillar sheet metal for damage. Install a new rivet nut if
necessary.
Position the bracket and install the bolt for the tether cord to the A-pillar.
10. Make sure the tether is securely engaged into the pin-type retainer and install the pin-type
retainer to the A-pillar.
- If a new safety canopy module was not installed, route the tether and securely engage it into the
pin-type retainer at the A-pillar.
Vehicles with a moonroof
11. Route and connect the moonroof drain tube.
All vehicles
12. Connect the safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8003
13. WARNING:
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
- Vehicles equipped with safety canopy modules require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety
canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets
each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety
canopy module deployment.
Install the headliner.
14. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8007
Air Bag Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8008
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8009
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed, erroneous DTCs will result.
The restraints control module (RCM) carries out the following functions:
- deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioners to remove slack from the safety belt.
- monitors the SRS for faults.
- illuminates the air bag indicator if a fault is detected.
- flashes the air bag indicator to indicate the lamp fault code (LFC) detected.
- communicates through the data link connector (DLC) the current or historical Diagnostic Trouble
Codes (DTCs).
- signals the instrument cluster module to activate a chime if the air bag indicator is not available
and another SRS fault exists.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the ON position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC. If an SRS fault exists, 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 DLC, to the scan tool. If the air bag indicator does not function, and the
system detects a fault condition, the RCM will signal the instrument cluster module to activate an
audible chime. The chime is a series of 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. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the front air bags and safety belt pretensioners in the event that the ignition circuit is lost or
damaged during impact. The backup power supply will deplete its stored energy approximately one
minute after the battery ground cable is disconnected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8010
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Removal
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for proper air bag supplemental restraint
system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision
in which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
All vehicles 1. Depower the system.
Vehicles with a center console 2. Remove the center console.
Vehicles with 60/40 front bench seat 3. Remove the 60 percent portion of the front bench seat.
4. Remove the nuts and the restraints control module (RCM) top bracket.
5. WARNING: Do not handle, move or change the original horizontal mounting position of the
restraints control module (RCM) while the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8011
RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in
the inadvertent deployment of the safety canopy and risk of personal injury.
Separate the RCM from the bracket. 1
Remove the nuts.
2 Separate the RCM from the bracket.
All vehicles
6. Disconnect the small restraints control module (RCM) electrical connector.
1 Push down to release the retaining tab.
2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector.
7. Disconnect the large RCM electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM,
disengaging the lever.
2 Pull out and disconnect the large RCM electrical connector.
Vehicles with 60/40 front bench seat 8. Remove the RCM.
Vehicles with a center console
9. Remove the RCM.
1 Remove the RCM bracket bolts.
2 Remove the RCM with bracket.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8012
Vehicles with a center console
1. WARNING: The tightening torque of the air bag restraints control module (RCM) bracket
retaining bolts is critical for correct system
operation.
Install the RCM. 1
Position the RCM with bracket.
2 Install the bolts.
All vehicles
2. Make sure the connector position assurance lever is in the full release position before attempting
to connect the connector.
3. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
Position the large RCM electrical connector into the RCM.
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and slight resistance is felt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8013
4. Connect the RCM electrical connector.
- Pivot the connector position assurance lever toward the RCM, drawing the connector in to the
RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
5. Connect the small RCM electrical connector.
Vehicles with 60/40 front bench seat
6. WARNING: The tightening torque of the air bag restraints control module (RCM) to bracket
retaining nuts is critical for correct system
operation.
Install the RCM. 1
Position the RCM to the bracket. While positioning the RCM onto the bracket, make sure the wire harness is positioned between the
RCM and the bracket shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 8014
2 Install the nuts.
7. Position the RCM top bracket and install the nuts.
Vehicles with a center console 8. Install the center console.
Vehicles with 60/40 front bench seat 9. Install the 60 percent portion of the front bench seat.
All vehicles 10. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Diagrams >
Page 8018
Air Bag Resistor: Description and Operation
SAFETY CANOPY BRIDGE RESISTOR
CAUTION: Do not deactivate the safety canopy module circuit by removing the bridge resistor from
the electrical connector.
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated.
The safety canopy bridge resistor:
- is equipped only on Expedition, without optional safety canopy modules.
- must not be removed during deactivation.
- can be accessed with the headliner dropped and is located just behind the RH side second row
courtesy light.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Diagrams >
Page 8019
Air Bag Resistor: Service and Repair
SAFETY CANOPY BRIDGE RESISTOR
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.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- There is only one safety canopy bridge resistor. The bridge resistor can be accessed with the
headliner dropped and is located just behind the RH side second row courtesy light.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Lower but do not remove the headliner.
3. Remove the safety canopy bridge resistor.
- Release the safety canopy bridge resistor from the adhesive.
- Disconnect and remove the safety canopy bridge resistor.
Installation
1. Install the safety canopy bridge resistor.
- Connect the electrical connector.
- Position the safety canopy bridge resistor. Apply an appropriate adhesive to hold the safety canopy bridge resistor in place.
2. Install the headliner. 3. Repower the system. 4. Check the active restraint system for correct
operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams
Clockspring Assembly / Spiral Cable: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8023
Clockspring Assembly / Spiral Cable: Description and Operation
CLOCKSPRING
The clockspring:
- is mounted on the steering column, behind the steering wheel.
- allows for continuous electrical connections between the driver air bag module and the restraints
control module (RCM) when the steering wheel is turned.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8024
Clockspring Assembly / Spiral Cable: Service and Repair
CLOCKSPRING
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
All vehicles 1. Depower the system.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8025
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
5. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
6. Release the tab and disconnect the driver air bag module accessories electrical connector at the
top of the clockspring and remove the driver air
bag module.
All vehicles 7. Make sure the road wheels are in the straight-ahead position.
8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the steering
wheel removal and installation procedure.
Remove the steering wheel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8026
9. Apply two strips of masking tape across the clockspring to prevent accidental rotation when the
clockspring is removed.
10. Release the tabs and slide the gear selector cover away from the steering column shrouds.
11. From under the steering column, remove the three screws and the lower steering column
shroud.
12. From under the steering column remove the screw and then remove the upper steering column
shroud.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8027
13. Separate the multi-function switch from the clockspring.
1 Remove the screw.
2 Release the tab.
3 While releasing the retaining tab, slide the multi-function switch up and out of the way.
14. Separate the clockspring from the steering column.
1 Remove the screws.
2 Slide the clockspring off the steering column shaft.
15. Remove the clockspring.
1 Disconnect the clockspring electrical connectors.
2 Remove the clockspring.
16. Inspect the clockspring bracket for damage and remove as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8028
Installation
Vehicles to receive a new clockspring bracket
1. Install the clockspring bracket and screws.
Vehicles receiving a new clockspring
2. NOTE: A new clockspring is supplied in a centralized position and held there with a key.
Remove the key from the clockspring, holding the rotor in its centralized position. Do not allow the clockspring rotor to turn.
Vehicles needing clockspring recentering
3. WARNING: Incorrect centralization may result in premature component failure. If in doubt when
centralizing the clockspring, repeat
the centralizing procedure. Failure to follow this instruction may result in personal injury.
CAUTION: Make sure the road wheels are in the straight-ahead position.
NOTE: If a clockspring has rotated out of center, follow through with this step.
Centralize the clockspring. 1
Hold the clockspring outer housing stationary.
2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and
can be broken from its internal connection.
While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length. Stop
turning when a slight resistance is felt.
3 Turn the clockspring clockwise approximately 2.75 turns. This is the center point of the
clockspring. Do not allow the rotor to turn from this position.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8029
4. NOTE: Make sure the battery negative cable is disconnected before continuing with the
installation procedure.
Connect the clockspring electrical connectors.
5. NOTE: Slight turning of the clockspring rotor is allowable for alignment purposes to the steering
column.
Install the clockspring onto the steering column. 1
With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring
onto the steering column.
2 Install the screws.
Vehicle repairs using the same clockspring 6. Remove the tape applied during clockspring removal.
All vehicles
7. Install the multi-function switch.
1 Align the multi-function switch and slide it down into position.
2 Check that the retaining tab is engaged.
3 Install the screw.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8030
8. Position the upper steering column shroud, and from under the steering column, install the
screw.
9. Position the lower steering column shroud and install the three screws.
10. Reposition the gear selector cover to the steering column shrouds and engage the tabs.
11. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the steering
wheel removal and installation procedure.
Install the steering wheel.
Expedition vehicles
12. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8031
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during the deactivation
procedure.
3 Position the driver air bag module to the steering wheel.
Navigator vehicles
13. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
14. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
All vehicles
15. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 8032
16. Install the two steering wheel back cover plugs (one shown). 17. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor > Page 8037
Impact Sensor: Locations Safety Canopy Sensor
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor > Page 8038
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor > Page 8039
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor > Page 8040
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor > Page 8043
Impact Sensor: Diagrams Safety Canopy Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor > Page 8044
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Page 8045
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
For these vehicles, the SRS uses up to eight sensors. Within the RCM there can be up to three
safing sensors which are not separately serviced. The RCM will always have at least one safing
sensor for front impact. Two more safing sensors are used if the vehicle is equipped with safety
canopy modules. The RCM is mounted to the center tunnel beneath the console or bench seat. All
vehicles will have a front impact severity sensor that is located in the front-center of the vehicle,
mounted near the bottom of the hood latch support bracket. If the vehicle is equipped with safety
canopy modules, there are four additional side impact sensors external to the RCM. One front row
side impact sensor is located behind each of the front door interior trim panels. One second row
side impact sensor is located at the base of each C-pillar. Mounting orientation is critical for correct
operation of all impact and rollover sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Side Impact Sensor - Second Row
Impact Sensor: Service and Repair Side Impact Sensor - Second Row
SIDE IMPACT SENSOR - SECOND ROW
Removal
WARNING:
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The driver side is shown, the passenger side is similar.
- 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. Depower the system. 2. Remove the rear door scuff plate.
3. Separate the rear quarter trim panel.
1 Remove the safety belt anchor.
2 Pull out at the front of the rear quarter trim panel, releasing the retaining clips, allowing access to
the side impact sensor.
4. Remove the side impact sensor.
1 Remove the bolt.
2 Disconnect and remove the side impact sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Side Impact Sensor - Second Row > Page 8048
1. Make sure the second row side impact sensor tabs are aligned to the bracket.
2. Install the second row side impact sensor with bracket.
1 Align and insert the second row side impact sensor bracket locator pin to the opening in the
quarter panel sheet metal.
2 Install the bolt.
3 Connect the electrical connector.
3. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Install the rear quarter trim panel. 1
Align the rear quarter trim panel and push in, seating the retaining clips.
2 Install the safety belt anchor.
4. Install the rear door scuff plate. 5. Repower the system. 6. Check the active restraint system for
correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Side Impact Sensor - Second Row > Page 8049
Impact Sensor: Service and Repair Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
Removal
WARNING:
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Depower the system.
2. Remove the pin-type retainers and lower the front lower splash shield to access the front impact
severity sensor.
3. NOTE: The front impact severity sensor is mounted on the bottom of the hood latch support
bracket.
Remove the front impact severity sensor. 1
Remove the nut.
2 Disconnect and remove the front impact severity sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Side Impact Sensor - Second Row > Page 8050
1. CAUTION: If the hood latch support bracket or weld stud are damaged in any way that would
affect the way the front impact severity
sensor mounts to its original manufactured position, a new hood latch support bracket must be
installed.
NOTE: Make sure the hood latch support bracket and front impact severity sensor mating surfaces
are clean and debris free.
Position the front impact severity sensor. 1
Position the front impact severity sensor onto the hood latch support bracket stud.
2 While sliding the front impact severity sensor onto the stud, align the locator tabs to the hood
latch support bracket alignment holes.
2. Install the front impact severity sensor.
1 With the front impact severity sensor sitting flat up against the hood latch support bracket, install
the nut.
2 Connect the front impact severity sensor.
3. Position the front lower splash shield and install the pin-type retainers. 4. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Side Impact Sensor - Second Row > Page 8051
Impact Sensor: Service and Repair Side Impact Sensor - Front Row
SIDE IMPACT SENSOR - FRONT ROW
Removal
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON.
This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The driver side is shown, the passenger side is similar.
- 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. Depower the system. 2. Remove the front interior door trim panel on the side with the affected
side impact sensor.
3. Separate the weathershield enough to access the side impact sensor.
4. Remove the side impact sensor.
1 Remove the bolt.
2 Disconnect the electrical connector.
3 Remove the side impact sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Side Impact Sensor - Second Row > Page 8052
1. CAUTION: Always replace the J-clip retaining nut whenever installing a side impact sensor.
Align the locator tabs to the openings in the door.
2. CAUTION:
- The ground wire must be placed between the bolt head and the sensor. Never position the ground
wire between the J-clip retaining nut and the sensor.
- Always replace the J-clip retaining nut whenever installing a side impact sensor.
Install the side impact sensor. 1
Connect the electrical connector.
2 With the locator tabs aligned to the openings in the door, position the side impact sensor to the
door.
3 Position the ground wire between the bolt head and the sensor.
4 Install the bolt.
3. Position back the weathershield. 4. Install the front interior door trim panel on the side with the
affected side impact sensor. 5. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8057
Air Bag Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8058
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8059
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed, erroneous DTCs will result.
The restraints control module (RCM) carries out the following functions:
- deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioners to remove slack from the safety belt.
- monitors the SRS for faults.
- illuminates the air bag indicator if a fault is detected.
- flashes the air bag indicator to indicate the lamp fault code (LFC) detected.
- communicates through the data link connector (DLC) the current or historical Diagnostic Trouble
Codes (DTCs).
- signals the instrument cluster module to activate a chime if the air bag indicator is not available
and another SRS fault exists.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the ON position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC. If an SRS fault exists, 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 DLC, to the scan tool. If the air bag indicator does not function, and the
system detects a fault condition, the RCM will signal the instrument cluster module to activate an
audible chime. The chime is a series of 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. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the front air bags and safety belt pretensioners in the event that the ignition circuit is lost or
damaged during impact. The backup power supply will deplete its stored energy approximately one
minute after the battery ground cable is disconnected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8060
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Removal
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for proper air bag supplemental restraint
system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision
in which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
All vehicles 1. Depower the system.
Vehicles with a center console 2. Remove the center console.
Vehicles with 60/40 front bench seat 3. Remove the 60 percent portion of the front bench seat.
4. Remove the nuts and the restraints control module (RCM) top bracket.
5. WARNING: Do not handle, move or change the original horizontal mounting position of the
restraints control module (RCM) while the
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8061
RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in
the inadvertent deployment of the safety canopy and risk of personal injury.
Separate the RCM from the bracket. 1
Remove the nuts.
2 Separate the RCM from the bracket.
All vehicles
6. Disconnect the small restraints control module (RCM) electrical connector.
1 Push down to release the retaining tab.
2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector.
7. Disconnect the large RCM electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM,
disengaging the lever.
2 Pull out and disconnect the large RCM electrical connector.
Vehicles with 60/40 front bench seat 8. Remove the RCM.
Vehicles with a center console
9. Remove the RCM.
1 Remove the RCM bracket bolts.
2 Remove the RCM with bracket.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8062
Vehicles with a center console
1. WARNING: The tightening torque of the air bag restraints control module (RCM) bracket
retaining bolts is critical for correct system
operation.
Install the RCM. 1
Position the RCM with bracket.
2 Install the bolts.
All vehicles
2. Make sure the connector position assurance lever is in the full release position before attempting
to connect the connector.
3. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
Position the large RCM electrical connector into the RCM.
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and slight resistance is felt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8063
4. Connect the RCM electrical connector.
- Pivot the connector position assurance lever toward the RCM, drawing the connector in to the
RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
5. Connect the small RCM electrical connector.
Vehicles with 60/40 front bench seat
6. WARNING: The tightening torque of the air bag restraints control module (RCM) to bracket
retaining nuts is critical for correct system
operation.
Install the RCM. 1
Position the RCM to the bracket. While positioning the RCM onto the bracket, make sure the wire harness is positioned between the
RCM and the bracket shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 8064
2 Install the nuts.
7. Position the RCM top bracket and install the nuts.
Vehicles with a center console 8. Install the center console.
Vehicles with 60/40 front bench seat 9. Install the 60 percent portion of the front bench seat.
All vehicles 10. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-9-17 > May >
05 > Restraints/Instruments - Can't Disable Seat Belt Chime
Seat Belt Control Module: Customer Interest Restraints/Instruments - Can't Disable Seat Belt
Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-9-17 > May >
05 > Restraints/Instruments - Can't Disable Seat Belt Chime > Page 8073
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: >
05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt Chime
Seat Belt Control Module: All Technical Service Bulletins Restraints/Instruments - Can't Disable
Seat Belt Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: >
05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt Chime > Page 8079
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8085
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8086
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8087
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8088
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8089
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8090
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8091
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8092
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8093
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8094
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8095
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8096
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 8097
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Description and Operation
Child Seat Tether Attachment: Description and Operation
Attaching Safety Seats With Tether Straps
Some manufacturers make child safety seats that include a tether strap that goes over the back of
the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as
an accessory. Contact the manufacturer of the child safety seat for information about ordering a
tether strap.
Child safety seat tether anchors are manufactured into the vehicle. See the active restraint system
component location at the Owner's Literature for locations.
For removal and installation of child safety seat tether anchors, refer to the appropriate procedure
or Seats for seat cushion frame replacement.
Lower Anchors and Tethers for Children (LATCH)
The lower anchors and tethers for children (LATCH) system is a standardized and uniform
attachment system for installing child safety seats in passenger vehicles. LATCH-equipped child
safety seats have two lower attachments that connect to the vehicle portion of the LATCH system.
The vehicle portion of the system consists of two attachment points (6mm wires) welded to the rear
seat cushion frame. The attachment points protrude from the bite line between the seat cushion
and seat backrest.
If a child safety seat was in use during a collision, inspect the vehicle portion of the system for
damage. If any of the attachment points (6mm wires) are damaged, install a new seat cushion
frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Description and Operation > Page 8102
Child Seat Tether Attachment: Service and Repair
CHILD SAFETY SEAT TETHER ANCHOR
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Position the third row seat backrest down.
2. Release the seat back J-clips.
3. With the seat backrest trim cover and cushion positioned out of the way, remove the bolt and the
child safety seat tether anchor.
4. WARNING: It is important that the bolt/anchor be securely tightened to specification. Otherwise,
the child's safety seat may not be
correctly secured, and the child could be injured in case of a sudden stop or accident.
NOTE: Inspect the seat for damage. If the seat is found to be damaged, install new seat components.
- Make sure to tighten the bolts to specification.
To install, reverse the removal procedure.
5. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and
Operation
Seat Belt: Description and Operation
FASTENING SAFETY BELTS
WARNING: Do not introduce slack into the safety belt system because the belt locks upon impact
where it is positioned. Use the shoulder safety belt on the outside shoulder only. Never wear the
shoulder safety belt under the arm. Never swing the shoulder safety belt around the neck over the
inside shoulder. Never use a single belt for more than one person. Make sure the lap portion of the
belt is fitted snugly and as low as possible around the hips, not the waist. Failure to follow these
precautions could increase the chance and severity of injury in a collision.
Always follow the preceding safety precautions when fastening the safety belts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement
Seat Belt: Service and Repair Replacement of The Weld Nut and Reinforcement
REPLACEMENT OF THE WELD NUT AND REINFORCEMENT
1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut
only or the weld nut and reinforcement and weld nut are missing. If the B- or C- or D-pillar safety
belt anchor nuts or
reinforcements are stripped or missing, a new nut or reinforcement should be installed. To install a
missing weld nut only, proceed to Step 3.
3. Obtain the correct M12 weld nut and a standard washer to perform the procedure. 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 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement > Page 8108
Seat Belt: Service and Repair Safety Belt Twisted At The Safety Belt Guide - Outboard
SAFETY BELT TWISTED AT THE SAFETY BELT GUIDE - OUTBOARD
1. Straighten the twisted belt webbing.
1 Grasp webbing at the safety belt guide.
2 Feed twisted portion of webbing up through safety belt guide.
2. Pull straightened belt downward to check for proper operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement > Page 8109
Seat Belt: Service and Repair Safety Belt Cleaning
SAFETY BELT CLEANING
1. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken.
Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery
or carpets. Follow the instructions provided with the soap.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement > Page 8110
Seat Belt: Service and Repair Safety Belt With Anchor Plate Thread Damage
SAFETY BELT WITH ANCHOR PLATE THREAD DAMAGE
1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt
anchor plate with a 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat
belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with
the repair parts indicated in the Safety Belt Parts Replacement Guidelines. 6. When repairing a
multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the
floorpan.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement > Page 8111
Seat Belt: Service and Repair
Replacement of The Weld Nut and Reinforcement
REPLACEMENT OF THE WELD NUT AND REINFORCEMENT
1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut
only or the weld nut and reinforcement and weld nut are missing. If the B- or C- or D-pillar safety
belt anchor nuts or
reinforcements are stripped or missing, a new nut or reinforcement should be installed. To install a
missing weld nut only, proceed to Step 3.
3. Obtain the correct M12 weld nut and a standard washer to perform the procedure. 4. Drill out two
8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding
wire and feed through clearance hole in door frame opening until it becomes visible at the access
hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire
back up to the weld nut clearance hole. 8. Hold the weld nut securely in place. Use the MIG Wire
Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in) diameter
holes previously drilled.
9. Metal finish as required.
10. Verify the nut is securely in place.
Safety Belt Twisted At The Safety Belt Guide - Outboard
SAFETY BELT TWISTED AT THE SAFETY BELT GUIDE - OUTBOARD
1. Straighten the twisted belt webbing.
1 Grasp webbing at the safety belt guide.
2 Feed twisted portion of webbing up through safety belt guide.
2. Pull straightened belt downward to check for proper operation.
Safety Belt Cleaning
SAFETY BELT CLEANING
1. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken.
Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery
or carpets. Follow the instructions provided with the soap.
Safety Belt With Anchor Plate Thread Damage
SAFETY BELT WITH ANCHOR PLATE THREAD DAMAGE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement > Page 8112
1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt
anchor plate with a 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat
belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with
the repair parts indicated in the Safety Belt Parts Replacement Guidelines. 6. When repairing a
multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the
floorpan.
Safety Belt Tongue Rotated on Belt
SAFETY BELT TONGUE ROTATED ON BELT
1. Fold the safety belt as indicated.
2. Pull the safety belt tongue over the fold in the safety belt.
Safety Belt - Front Row, Center
SAFETY BELT - FRONT ROW, CENTER
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Replacement of The Weld Nut and Reinforcement > Page 8113
1. Remove the safety belt bolt and route the safety belt out from the seat.
2. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. 1
When installing, make sure the safety belt anchor is on top of the seat bracket.
2 Make sure the safety belt is accessible to the occupant after installation.
3. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Description and Operation
Seat Belt Buckle: Description and Operation
SAFETY BELT BUCKLE AND PRETENSIONER
NOTE: There is currently no restraint system diagnostic tool for the safety belt buckle pretensioner
under the seat connectors. If the ignition switch is turned to the ON or START position with the
safety belt buckle pretensioner electrical connector(s) disconnected, the DTC and flagged faults for
an open circuit will be activated.
The safety belt buckle and pretensioners are for the front outboard occupants, located on the
inboard side of the seats. This allows the front safety belt buckle end to move with the front seat.
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from
the safety belt system. When the front air bag system is deployed, the pretensioner in the buckle
deploys, causing the buckle to move downward, pulling excess webbing from the lap and shoulder
safety belts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center
Seat Belt Buckle: Service and Repair Front Safety Belt Buckle - Center
FRONT SAFETY BELT BUCKLE - CENTER
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Remove the safety belt buckle bolt and route the safety belt buckle out of the seat.
2. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. Make sure the safety belt buckle is accessible to the occupant after installation.
3. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8119
Seat Belt Buckle: Service and Repair Rear Safety Belt Buckle - Second Row, 20 Percent Seat
REAR SAFETY BELT BUCKLE - SECOND ROW, 20 PERCENT SEAT
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Remove the second row 20 percent seat.
2. Remove the screws and the pin-type retainer (not shown), and remove the inboard side shield.
- It may be necessary to fold the seat to remove the side shield.
3. Remove the nut and the safety belt buckle.
4. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame.
5. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8120
Seat Belt Buckle: Service and Repair Rear Safety Belt Buckle - Second Row, 40 Percent Seat
REAR SAFETY BELT BUCKLE - SECOND ROW, 40 PERCENT SEAT
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The LH side 40 percent seat is shown, the RH side is similar.
1. Pivot the 40 percent seat up.
2. Remove the seat side shield.
1 Remove the two screws.
2 Slide up and remove the side shield.
3. Remove the screws and the lower pedestal cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8121
4. Remove the safety belt buckle bolt and the safety belt buckle.
5. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame.
6. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8122
Seat Belt Buckle: Service and Repair Rear Safety Belt Buckle - Third Row, 40 Percent Seat
REAR SAFETY BELT BUCKLE - THIRD ROW, 40 PERCENT SEAT
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Remove the 40 percent third row seat.
2. Remove the bolt and the safety belt buckle.
3. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle, make sure to engage the anti-rotation tab to the sheet metal.
- Make sure the safety belt buckle is accessible to the passenger after installation.
4. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8123
Seat Belt Buckle: Service and Repair
Front Safety Belt Buckle - Center
FRONT SAFETY BELT BUCKLE - CENTER
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Remove the safety belt buckle bolt and route the safety belt buckle out of the seat.
2. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. Make sure the safety belt buckle is accessible to the occupant after installation.
3. Check the active restraint system for correct operation.
Rear Safety Belt Buckle - Second Row, 20 Percent Seat
REAR SAFETY BELT BUCKLE - SECOND ROW, 20 PERCENT SEAT
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Remove the second row 20 percent seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8124
2. Remove the screws and the pin-type retainer (not shown), and remove the inboard side shield.
- It may be necessary to fold the seat to remove the side shield.
3. Remove the nut and the safety belt buckle.
4. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame.
5. Check the active restraint system for correct operation.
Rear Safety Belt Buckle - Second Row, 40 Percent Seat
REAR SAFETY BELT BUCKLE - SECOND ROW, 40 PERCENT SEAT
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The LH side 40 percent seat is shown, the RH side is similar.
1. Pivot the 40 percent seat up.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8125
2. Remove the seat side shield.
1 Remove the two screws.
2 Slide up and remove the side shield.
3. Remove the screws and the lower pedestal cover.
4. Remove the safety belt buckle bolt and the safety belt buckle.
5. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame.
6. Check the active restraint system for correct operation.
Rear Safety Belt Buckle - Third Row, 40 Percent Seat
REAR SAFETY BELT BUCKLE - THIRD ROW, 40 PERCENT SEAT
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Remove the 40 percent third row seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8126
2. Remove the bolt and the safety belt buckle.
3. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle, make sure to engage the anti-rotation tab to the sheet metal.
- Make sure the safety belt buckle is accessible to the passenger after installation.
4. Check the active restraint system for correct operation.
Rear Safety Belt Buckle - Third Row, 60 Percent Seat
REAR SAFETY BELT BUCKLE - THIRD ROW, 60 PERCENT SEAT
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
1. Position the third row seats down.
2. Remove the rear load floor panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8127
3. Remove the mid-floor panel support.
1 Remove the jack assembly.
2 Remove the two pin-type retainers (not shown).
3 Remove the two bolts.
4 Position the load floor panels up, lift on the front of the mid-floor panel support to release the
three retaining clips (not shown) and remove the support panel.
4. Remove the bolt and the safety belt buckle assembly.
5. NOTE: Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt buckle assembly, make sure to engage the anti-rotation tab to the
sheet metal.
- Make sure the safety belt buckles are accessible to the passengers after installation.
6. Check the active restraint system for correct operation.
Safety Belt Buckle and Pretensioner - 40 Percent Seat
SAFETY BELT BUCKLE AND PRETENSIONER - 40 PERCENT SEAT
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The LH forty percent seat is shown, the RH forty percent seat is similar.
1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 40
percent front seat on the side with the affected safety belt buckle and pretensioner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8128
4. Release the J-clip.
5. Release the hook-and-loop strip and pull the seat cushion trim cover up enough to expose the
safety belt buckle and pretensioner.
6. NOTE: Make note of the wire harness routing for installation.
Remove the safety belt buckle and pretensioner electrical connectors from the seat cushion frame.
Disconnect the usage detection switch electrical connector.
- Separate the safety belt buckle pretensioner electrical connector from the pin-type retainer.
7. NOTE: Make note of the wire harness routing for installation.
Remove the safety belt buckle and pretensioner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8129
1 Route out the safety belt buckle and pretensioner usage detection switch and pretensioner
electrical connectors.
2 Remove the nut.
3 Remove the safety belt buckle and pretensioner.
Installation
1. Align the safety belt buckle and pretensioner anti-rotation tab to the seat bracket.
2. Install the safety belt buckle and pretensioner.
1 With the anti-rotation tab aligned, position the safety belt buckle and pretensioner to the seat.
2 Install the nut.
3 Route the safety belt buckle and pretensioner usage detection switch and pretensioner electrical
connectors as noted in removal.
3. Reposition the safety belt buckle and pretensioner electrical connectors to the seat cushion
frame.
- Connect the usage detection switch electrical connector.
- Reposition the pin-type retainer to the safety belt buckle pretensioner electrical connector and
install it under the seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8130
4. Reposition the seat cushion trim cover over the safety belt buckle and pretensioner and attach
the hook-and-loop strip.
5. Attach the seat backrest J-clip to the seat cushion frame. 6. Install the 40 percent front seat on
the side with the affected safety belt buckle and pretensioner. 7. Repower the SRS. 8. Check the
active restraint system for correct operation.
Safety Belt Buckle and Pretensioner - 60 Percent Seat
SAFETY BELT BUCKLE AND PRETENSIONER - 60 PERCENT SEAT
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 60
percent front seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8131
4. NOTE: Make note of the wire harness routing for installation.
Detach the electrical connectors and route out the wire harnesses.
5. Remove the safety belt buckle and pretensioner.
1 Remove the nut.
2 Pull the buckle end back through the seat cushion and remove the safety belt buckle and
pretensioner.
Installation
1. Install the safety belt buckle and pretensioner.
1 Position the safety belt buckle and pretensioner to the seat. Align the safety belt buckle and pretensioner locator tab to the hole in the seat frame.
- Check that the safety belt buckle end is accessible after positioning.
2 Install the nut.
3 Route the safety belt buckle and pretensioner usage detection switch and pretensioner electrical
connectors as noted in removal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Front Safety Belt Buckle - Center > Page 8132
2. Attach the electrical connectors and route the wire harnesses as noted in removal. 3. Install the
60 percent front seat. 4. Repower the SRS. 5. Check the active restraint system for correct
operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Driver
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Driver > Page 8138
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Page 8139
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the supplemental restraint system (SRS), the driver and front outboard passenger safety
belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches indicate
to the restraints control module (RCM) whether the safety belts are connected or disconnected.
The RCM uses this information in determining the deployment rate of the dual-stage driver and
passenger air bag modules.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Customer Interest: > 05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt
Chime
Seat Belt Control Module: Customer Interest Restraints/Instruments - Can't Disable Seat Belt
Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Customer Interest: > 05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt
Chime > Page 8148
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 05-9-17 > May > 05 > Restraints/Instruments - Can't Disable
Seat Belt Chime
Seat Belt Control Module: All Technical Service Bulletins Restraints/Instruments - Can't Disable
Seat Belt Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 05-9-17 > May > 05 > Restraints/Instruments - Can't Disable
Seat Belt Chime > Page 8154
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH
Steering Gear: All Technical Service Bulletins Steering/Tires/Wheels - Steering Wheel Nibble at
65MPH
TSB 05-7-2
04/18/05
STEERING WHEEL NIBBLE AT 65 MPH (105 KM/H) OR HIGHER
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 03-12-07 to add model years and update the Service Procedure.
ISSUE Some Expedition/Navigator may exhibit a steering wheel nibble (side-to-side or rotational
oscillation) at 65 MPH (105 km/h) or higher.
ACTION Refer to the Diagnostic Overview. Based on the customer's description of the concern,
find the appropriate Operating Condition and Probable Cause. If the vehicle concern and operating
conditions match those on the Diagnostic Overview, follow the TSB Service Procedure to repair.
NOTE
IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS
WHEN THE VIBRATION OR NIBBLE IS OCCURRING TO PROPERLY DIAGNOSE AND REPAIR
THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC
VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO
CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ).
SERVICE INFORMATION
NOTE
NIBBLE CANNOT BE ELIMINATED WITHOUT PROPER TIRE AND WHEEL BALANCE.
1. Drive the vehicle at highway speeds for at least 20 miles (33 km) to eliminate the flat spotting.
Install an EVA or Vetronix vibration analyzer and have an assistant monitor and record the reading
near the end of the 20 miles (33 km) drive and while at the peak of the vibration.
a. If the vibration goes away during the 20 mile (33 km) drive, the concern is due to temporary tire
flat spotting which is a normal tire condition. Do not continue with this TSB.
b. If the vibration remains, proceed to Step 2 for 4x4 vehicles, or to Step 3 for 4x2 vehicles.
NOTE
THE VEHICLE MUST BE DRIVEN TO REMOVE TIRE FLAT SPOTS, THE TIRE BALANCE AND
ROAD FORCE MEASUREMENTS MAY BE INACCURATE OTHERWISE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH > Page 8160
2. Check the Integrated Wheel End (IWE) on 4x4 units. Raise the front of the vehicle (wheels off
the ground), engine running, and vehicle in 2WD mode. The front half shafts should not turn when
wheels are rotated by hand.
a. If the IWE is functioning correctly, proceed to Step 3.
b. If not, refer to Workshop Manual Section 308-07 and repair IWE first, then proceed to Step 3.
NOTE
THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE
MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK
RUN OUT WHEN ABSOLUTELY NECESSARY. VISIT WEBSITE (WWW.G5P9700.COM) TO
LOCATE THE NEAREST FACILITY THAT HAS THIS TYPE OF EQUIPMENT.
3. If road force measurement equipment (Hunter GSP 9700, 9712, or equivalent) is available,
proceed to Step 4. If not, balance the tires with a standard balancer and use a dial indicator to
locate and mark the high point of each tire's centerline radial runout. This will be used for the R1H
reading in the following steps. After marking the tires, proceed to Step 7.
NOTE
SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL
RESIDUALS TO BE DISPLAYED.
4. Perform the road force measurement immediately after driving the vehicle. Remove the wheel
cover and wheel assembly. Measure the road force variation of all four tires. Measure and mark the
tire HIGH road force variation point (R1H) on all four tires prior to dismounting them from the road
force measurement equipment. Balance as required to 0.35 oz (10g) or less of imbalance (check
both two-plane and static). If any wheel assembly measures more than 25 lbs R1H, then proceed
to Step 5. If less than 25 lbs R1H, proceed to Step 6.
5. Using the road force measurement equipment, determine the low spot of the wheel run out.
Match high point force variation on the tire with the low spot of wheel run out. If the wheel assembly
is now acceptable, continue with rebalance. If not, replace the tire and recheck.
NOTE
THE SPARE TIRE SHOULD NOT BE USED AS A REPLACEMENT TIRE.
6. Install the lowest R1H level tires on the front of the vehicle.
7. Position all tire/wheel assemblies on the hubs with the high R1H point, or high tire centerline
radial run out, at the 12:00 position (Figure 2).
8. Install the lug nuts and torque to 150 lb-ft (200 N.m).
9. Using a flat feeler gauge, check the wheel hub-to-bore clearance to verify the largest gap is as
close to the 6:00 position as possible (Figure 2). If the largest gap is not located near the 6:00
position, remove the lug nuts and tire/wheel assembly, rotate the hub to a new position, and
reinstall the tire/wheel assembly again following Steps 7 and 8. Check again for the optimum 6:00
gap location.
10. Road test vehicle to verify vehicle is corrected. If not corrected, proceed to Step 11.
11. Replace the steering gear per the following vehicle and build date information.
NOTE
DO NOT REPLACE THE STEERING GEAR UNLESS NIBBLE CANNOT BE RESOLVED WITH
TIRE/WHEEL BALANCE.
^ Expedition built from 3/17/2002-7/15/2002:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH > Page 8161
2L1Z-3504-KB
^ Expedition built from 7/15/2002-5/20/2004: 4L1Z-3504-AA
^ Expedition built after 5/20/2004: Do not replace the steering gear. These vehicles already contain
the latest level.
^ Navigator built from 3/18/2002-6/27/2003: 4L7Z-3504-AA
^ Navigator built after 6/27/2003: Do not replace the steering gear. These vehicles already contain
the latest level.
NOTE
WHEN REPLACING NAVIGATOR STEERING GEAR, ALSO REFER TO TSB 03-11-05 FOR
INFORMATION ON REPROGRAMMING THE IVD MODULE.
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: 03-11-05
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3504 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH > Page 8162
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH > Page 8168
2. Check the Integrated Wheel End (IWE) on 4x4 units. Raise the front of the vehicle (wheels off
the ground), engine running, and vehicle in 2WD mode. The front half shafts should not turn when
wheels are rotated by hand.
a. If the IWE is functioning correctly, proceed to Step 3.
b. If not, refer to Workshop Manual Section 308-07 and repair IWE first, then proceed to Step 3.
NOTE
THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE
MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK
RUN OUT WHEN ABSOLUTELY NECESSARY. VISIT WEBSITE (WWW.G5P9700.COM) TO
LOCATE THE NEAREST FACILITY THAT HAS THIS TYPE OF EQUIPMENT.
3. If road force measurement equipment (Hunter GSP 9700, 9712, or equivalent) is available,
proceed to Step 4. If not, balance the tires with a standard balancer and use a dial indicator to
locate and mark the high point of each tire's centerline radial runout. This will be used for the R1H
reading in the following steps. After marking the tires, proceed to Step 7.
NOTE
SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL
RESIDUALS TO BE DISPLAYED.
4. Perform the road force measurement immediately after driving the vehicle. Remove the wheel
cover and wheel assembly. Measure the road force variation of all four tires. Measure and mark the
tire HIGH road force variation point (R1H) on all four tires prior to dismounting them from the road
force measurement equipment. Balance as required to 0.35 oz (10g) or less of imbalance (check
both two-plane and static). If any wheel assembly measures more than 25 lbs R1H, then proceed
to Step 5. If less than 25 lbs R1H, proceed to Step 6.
5. Using the road force measurement equipment, determine the low spot of the wheel run out.
Match high point force variation on the tire with the low spot of wheel run out. If the wheel assembly
is now acceptable, continue with rebalance. If not, replace the tire and recheck.
NOTE
THE SPARE TIRE SHOULD NOT BE USED AS A REPLACEMENT TIRE.
6. Install the lowest R1H level tires on the front of the vehicle.
7. Position all tire/wheel assemblies on the hubs with the high R1H point, or high tire centerline
radial run out, at the 12:00 position (Figure 2).
8. Install the lug nuts and torque to 150 lb-ft (200 N.m).
9. Using a flat feeler gauge, check the wheel hub-to-bore clearance to verify the largest gap is as
close to the 6:00 position as possible (Figure 2). If the largest gap is not located near the 6:00
position, remove the lug nuts and tire/wheel assembly, rotate the hub to a new position, and
reinstall the tire/wheel assembly again following Steps 7 and 8. Check again for the optimum 6:00
gap location.
10. Road test vehicle to verify vehicle is corrected. If not corrected, proceed to Step 11.
11. Replace the steering gear per the following vehicle and build date information.
NOTE
DO NOT REPLACE THE STEERING GEAR UNLESS NIBBLE CANNOT BE RESOLVED WITH
TIRE/WHEEL BALANCE.
^ Expedition built from 3/17/2002-7/15/2002:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH > Page 8169
2L1Z-3504-KB
^ Expedition built from 7/15/2002-5/20/2004: 4L1Z-3504-AA
^ Expedition built after 5/20/2004: Do not replace the steering gear. These vehicles already contain
the latest level.
^ Navigator built from 3/18/2002-6/27/2003: 4L7Z-3504-AA
^ Navigator built after 6/27/2003: Do not replace the steering gear. These vehicles already contain
the latest level.
NOTE
WHEN REPLACING NAVIGATOR STEERING GEAR, ALSO REFER TO TSB 03-11-05 FOR
INFORMATION ON REPROGRAMMING THE IVD MODULE.
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: 03-11-05
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3504 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 05-7-2 > Apr > 05 >
Steering/Tires/Wheels - Steering Wheel Nibble at 65MPH > Page 8170
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Description and Operation
Seat Belt Extension: Description and Operation
SAFETY BELT EXTENSION ASSEMBLY
In certain cases, the safety belt may be too short, even when it is fully extended. About 20 cm (8 in)
can be added to the belt length by using a safety belt extension. Safety belt extensions are
available through any Ford or Lincoln Mercury dealer parts department at no cost. Safety belt
extensions are only available with black webbing. There are two extension assemblies available,
one for the front seating positions and one for the rear seating positions. They are not
interchangeable. Only use extensions manufactured by the same supplier as the safety belt.
Manufacturer identification is located at the end of the webbing on the label. Also, use the safety
belt extension only if the safety belt is too short for you when fully extended. Do not use the
extension to change the fit of the shoulder belt across the torso.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts
Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster With Stripped
Weld Nuts
SAFETY BELT SHOULDER HEIGHT ADJUSTER WITH STRIPPED WELD NUTS
D-Ring Installation Kit
Special 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. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out
any chips before proceeding.
Apply a suitable lubricant to the M14x1.5 tap with integral stop provided in D-Ring Installation Kit
and tap new threads.
4. Use a threaded insert provided in D-Ring Installation Kit and screw it into the retapped hole until
it is slightly below the surface.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 8178
5. NOTE: If the two bolts on the height adjuster are not stripped, refer to Safety Belt Shoulder
Height Adjuster-Front Row or Safety Belt Shoulder
Height Adjuster-Second Row. If the bolts are stripped, replace the height adjuster.
Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to
seat the insert keys.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 8179
Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster - Front Row
SAFETY BELT SHOULDER HEIGHT ADJUSTER - FRONT ROW
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The LH side is shown, the RH side is similar.
1. NOTE:
- Position the safety belt guide to the lowest position.
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or cover does not remain closed, install a new shoulder safety belt guide cover.
Remove the safety belt guide. Lift up on the cover and remove the nut.
2. Remove the upper B-pillar trim panel.
- Remove the bolt cover and bolt.
- Remove the upper B-pillar trim panel by releasing the clips and sliding the upper B-pillar panel
downward.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 8180
3. Remove the B-pillar trim panel.
4. Remove the safety belt height adjuster trim cover.
5. Remove the bolts and the safety belt shoulder height adjuster.
6. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. -
When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper B-pillar
trim panel.
7. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 8181
Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster - Second Row
SAFETY BELT SHOULDER HEIGHT ADJUSTER - SECOND ROW
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The LH side is shown, the RH side is similar.
1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide
cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row LH side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row LH side safety belt guide.
2. Remove the LH C-pillar trim panel.
1 Separate the weatherstripping along the LH C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the LH C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 8182
3. Remove the safety belt height adjuster trim cover.
4. Remove the bolts and the safety belt shoulder height adjuster.
5. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure.
6. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information
> Description and Operation
Seat Belt Reminder Buzzer: Description and Operation
Belt Minder (if equipped)
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently
sounding a chime and illuminating the safety belt warning lamp in the instrument cluster.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Description and Operation
Seat Belt Reminder Lamp: Description and Operation
Belt Minder (if equipped)
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently
sounding a chime and illuminating the safety belt warning lamp in the instrument cluster.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts
Slow to Retract
Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract
TSB 05-16-11
08/22/05
SAFETY BELT RETRACTION SPEED
FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport,
Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty,
Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape
Hybrid 2004-2006 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006
Monterey 2005-2006 Mariner
This article supersedes TSB 04-24-21 to update the vehicle model years.
ISSUE A service kit is now available to improve safety belt retraction speed.
ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet
included in the kit. Refer to Workshop Manual Section 501-20A for additional information.
NOTE
TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES
LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE
MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE
THREE VEHICLES.
NOTE
FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE
FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE
HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES.
^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on
vehicles built on/after 6/16/2003.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles
built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles
built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts
Slow to Retract > Page 8197
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 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract
Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract
TSB 05-16-11
08/22/05
SAFETY BELT RETRACTION SPEED
FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport,
Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty,
Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape
Hybrid 2004-2006 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006
Monterey 2005-2006 Mariner
This article supersedes TSB 04-24-21 to update the vehicle model years.
ISSUE A service kit is now available to improve safety belt retraction speed.
ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet
included in the kit. Refer to Workshop Manual Section 501-20A for additional information.
NOTE
TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES
LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE
MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE
THREE VEHICLES.
NOTE
FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE
FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE
HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES.
^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on
vehicles built on/after 6/16/2003.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles
built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles
built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 8203
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 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 8204
Seat Belt Retractor: Description and Operation
Dual Locking Mode Retractors
WARNING: After any vehicle collision, the safety belt system at all outboard seating positions
(except driver, which has no "automatic locking retractor" feature) must be checked by a qualified
technician to verify that the "automatic locking retractor" feature for child seats is still functioning
correctly, in addition to other checks for correct safety belt system function. A belt and retractor
assembly must be replaced if the safety belt assembly's "automatic locking retractor" feature or any
other safety belt function is not operating correctly when checked according to the procedures.
Failure to replace the Belt and Retractor assembly could increase the risk of injury in collisions.
NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make
sure it is not in the automatic locking retractor (ALR) mode after installation in the stowed position.
All outboard continuous-loop, three-point retractor systems, except the driver position, are
equipped with the dual locking mode system.
The emergency locking retractor (ELR) mode will allow the occupant freedom of movement, locking
tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR
mode helps to reduce the forward movement of the driver and passengers. The ELR mode is
continuously in operation at all seating positions.
The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode
is used when locking a child seat in at a seating position or when a tight belt fit is desired. The ALR
mode is automatically engaged when the webbing is fully extracted from the retractor and then
allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is
made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged
when most of the webbing is retracted back onto the spool.
The automatic locking mode must be used when installing a child safety seat in the front or rear
passenger seating positions where dual locking mode retractors are provided.
Energy Management Retractor
This vehicle has a safety belt system with an energy management feature at the front seating
positions to help further reduce the risk of injury in the event of a head-on collision.
The energy management retractor feature is designed to pay out webbing in a controlled manner.
This feature is designed to help reduce the belt force acting on the occupant's chest.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor
Seat Belt Retractor: Service and Repair Front Safety Belt Retractor
FRONT SAFETY BELT RETRACTOR
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The RH side is shown, the LH side is similar.
1. Remove the B-pillar trim panel.
2. Release the two pin-type retainers and the safety belt guide.
3. Remove the three bolts and the B-pillar trim panel bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8207
4. Remove the bolt and the safety belt retractor.
5. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. When installing the safety belt retractor, make sure to engage the anti-rotation tab to the sheet
metal.
- Remove the shipping clip after safety belt retractor installation.
6. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8208
Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor - Second and Third Row
REAR SAFETY BELT RETRACTOR - SECOND AND THIRD ROW
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The LH side is shown, the RH side is similar.
Both retractors 1. Remove the rear quarter trim panel.
- Before installing the third row safety belt anchor, make sure the floor slotted plastic insert is still
present. If it is not, another insert must be installed.
Third row retractor, driver side 2. Remove the vehicle jack.
Second row retractor
3. Remove the bolt and the second row safety belt retractor.
Third row retractor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8209
4. Remove the bolt and the third row safety belt retractor.
Both retractors
5. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. 1
When installing the safety belt retractor, make sure to engage the anti-rotation tab to the sheet
metal.
2 Remove the shipping clip after safety belt retractor installation.
6. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8210
Seat Belt Retractor: Service and Repair Rear Center Safety Belt Retractor - Second Row
REAR CENTER SAFETY BELT RETRACTOR - SECOND ROW
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The retractor may be equipped with an additional web stop button (small, thin, round button,
not to be confused with the larger web stop button) located on the safety belt webbing. This button
is only used for vehicle assembly and serves no other functional purpose. The button can possibly
be retracted under the trim bezel making it difficult to pull the safety belt webbing out of the
retractor. To service, remove this web stop button. Do not replace the safety belt retractor to
eliminate this condition. Any resulting appearance concerns with the webbing can be worked out by
hand.
1. Remove the second row 20 percent seat.
2. Remove the two screws (one shown) on the inside of the RH side shield.
3. Release the pin-type retainer and remove the side shields.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8211
4. Remove the screw on the inside of the LH side shield.
5. Release the pin-type retainer and remove the side shields.
6. Remove the left hinge side shield screw and remove the side shield.
7. Unsnap the recliner pull strap handle and pull the handle through the seat.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8212
8. Remove the seat belt anchor bolt.
9. Release the J-clip.
10. Remove the screw from the seat backrest support panel and release the J-clips under seat
backrest support panel.
11. Remove the seat belt guide cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8213
12. Invert the seat backrest cover and remove the two pin-type retainers.
13. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop
strip, or the hook-and-loop strip can be torn
from the seat backrest foam.
Remove the seat backrest cover.
14. Remove the seat backrest foam pad.
15. Remove the seat backrest support panel screws.
16. Remove the seat belt retractor cover screws and remove the cover.
17. Remove the seat belt retractor bolt.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8214
18. Pinch and release the seat belt retractor guide from the seat backrest frame and remove the
safety belt retractor.
19. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. 1
When installing the safety belt retractor, make sure to engage the anti-rotation tab to the sheet
metal.
2 Remove the shipping clip after safety belt retractor installation.
20. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8215
Seat Belt Retractor: Service and Repair Rear Center Safety Belt Retractor - Third Row
REAR CENTER SAFETY BELT RETRACTOR - THIRD ROW
Torx Bit, Safety Belt Bolt
Special Tool(s)
Removal and Installation
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether
attachments and attaching hardware should be inspected after any collision. All belt assemblies
should be replaced unless a qualified technician finds the assemblies show no damage and
operate correctly. Belt assemblies not in use during a collision should also be inspected and
replaced if either damage or incorrect operation is noted.
NOTE: The retractor may be equipped with an additional web stop button (small, thin, round button,
not to be confused with the larger web stop button) located on the safety belt webbing. This button
is only used for vehicle assembly and serves no other functional purpose. The button can possibly
be retracted under the trim bezel making it difficult to pull the safety belt webbing out of the
retractor. To service, remove this web stop button. Do not replace the safety belt retractor to
eliminate this condition. Any resulting appearance concerns with the webbing can be worked out by
hand.
All vehicles 1. Remove the third row 60 percent seat backrest.
2. Remove the seat belt anchor bolt.
3. Depress the tab and remove the head restraint.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8216
4. Release the J-clip.
5. Release the two J-clips.
Manual seat
6. Remove the seat backrest release handle screws and remove the handle and cable assembly.
All vehicles
7. Remove the seat belt guide.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8217
8. NOTE: The head restraint sleeve pins are not interchangeable, note location for installation.
Reach up into seat backrest, squeeze, release, and remove the head restraint sleeves.
9. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat backrest foam.
Invert the seat backrest trim cover and remove.
10. Remove the seat backrest foam pad.
11. Remove the four screws from the seat belt cover (two shown).
12. Remove the safety belt retractor bolt.
13. Pinch to release the seat belt guide and remove the seat belt assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Front Safety Belt Retractor > Page 8218
14. NOTE:
- Make sure the safety belt webbing is not twisted prior to installation.
- Make sure to tighten all nuts and bolts to specification.
To install, reverse the removal procedure. Remove the shipping clip after safety belt retractor installation.
15. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Safety Belt Pretensioner, Driver
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Safety Belt Pretensioner, Driver > Page 8223
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Safety Belt System
Seat Belt Tensioner: Description and Operation Safety Belt System
Pretensioner System
All Expeditions and Navigators have a pretensioner system used with the front outboard safety belt
buckles. This works in conjunction with the front air bag system mounted in the steering wheel and
instrument panel.
If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt
pretensioners, the driver and passenger seat belt system (including safety belt buckle and
pretensioners, safety belt retractors, and height adjusters), must be replaced.
For diagnostic information, refer to Air Bag Systems.
For pretensioner buckle disposal information, refer to Air Bag Systems.
Safety Belt Buckle and Pretensioner
NOTE: There is currently no restraint system diagnostic tool for the safety belt buckle pretensioner
under the seat connectors. If the ignition switch is turned to the ON or START position with the
safety belt buckle pretensioner electrical connector(s) disconnected, the DTC and flagged faults for
an open circuit will be activated.
The safety belt buckle and pretensioners are for the front outboard occupants, located on the
inboard side of the seats. This allows the front safety belt buckle end to move with the front seat.
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from
the safety belt system. When the front air bag system is deployed, the pretensioner in the buckle
deploys, causing the buckle to move downward, pulling excess webbing from the lap and shoulder
safety belts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Safety Belt System > Page 8226
Seat Belt Tensioner: Description and Operation Safety Belt Pretensioners
SAFETY BELT PRETENSIONERS
NOTE: There is currently no restraint system diagnostic tool for the safety belt buckle pretensioner
under the seat connectors. When diagnosing the safety belt buckle pretensioners, it will be
necessary to disconnect the affected safety belt buckle pretensioner pigtail harness connector on
the component and install a restraint system diagnostic tool.
As part of the SRS, the driver and front outboard passenger safety belt buckles are equipped with
pretensioners. The safety belt buckle pretensioners remove excess slack from the safety belt
webbing. The pretensioners are activated by the restraints control module (RCM) when the module
detects a crash event force exceeding a programmed limit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat
Seat Belt Tensioner: Service and Repair Safety Belt Buckle and Pretensioner - 40 Percent Seat
SAFETY BELT BUCKLE AND PRETENSIONER - 40 PERCENT SEAT
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The LH forty percent seat is shown, the RH forty percent seat is similar.
1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 40
percent front seat on the side with the affected safety belt buckle and pretensioner.
4. Release the J-clip.
5. Release the hook-and-loop strip and pull the seat cushion trim cover up enough to expose the
safety belt buckle and pretensioner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8229
6. NOTE: Make note of the wire harness routing for installation.
Remove the safety belt buckle and pretensioner electrical connectors from the seat cushion frame.
Disconnect the usage detection switch electrical connector.
- Separate the safety belt buckle pretensioner electrical connector from the pin-type retainer.
7. NOTE: Make note of the wire harness routing for installation.
Remove the safety belt buckle and pretensioner. 1
Route out the safety belt buckle and pretensioner usage detection switch and pretensioner
electrical connectors.
2 Remove the nut.
3 Remove the safety belt buckle and pretensioner.
Installation
1. Align the safety belt buckle and pretensioner anti-rotation tab to the seat bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8230
2. Install the safety belt buckle and pretensioner.
1 With the anti-rotation tab aligned, position the safety belt buckle and pretensioner to the seat.
2 Install the nut.
3 Route the safety belt buckle and pretensioner usage detection switch and pretensioner electrical
connectors as noted in removal.
3. Reposition the safety belt buckle and pretensioner electrical connectors to the seat cushion
frame.
- Connect the usage detection switch electrical connector.
- Reposition the pin-type retainer to the safety belt buckle pretensioner electrical connector and
install it under the seat.
4. Reposition the seat cushion trim cover over the safety belt buckle and pretensioner and attach
the hook-and-loop strip.
5. Attach the seat backrest J-clip to the seat cushion frame. 6. Install the 40 percent front seat on
the side with the affected safety belt buckle and pretensioner. 7. Repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8231
8. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8232
Seat Belt Tensioner: Service and Repair Safety Belt Buckle and Pretensioner - 60 Percent Seat
SAFETY BELT BUCKLE AND PRETENSIONER - 60 PERCENT SEAT
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 60
percent front seat.
4. NOTE: Make note of the wire harness routing for installation.
Detach the electrical connectors and route out the wire harnesses.
5. Remove the safety belt buckle and pretensioner.
1 Remove the nut.
2 Pull the buckle end back through the seat cushion and remove the safety belt buckle and
pretensioner.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8233
1. Install the safety belt buckle and pretensioner.
1 Position the safety belt buckle and pretensioner to the seat. Align the safety belt buckle and pretensioner locator tab to the hole in the seat frame.
- Check that the safety belt buckle end is accessible after positioning.
2 Install the nut.
3 Route the safety belt buckle and pretensioner usage detection switch and pretensioner electrical
connectors as noted in removal.
2. Attach the electrical connectors and route the wire harnesses as noted in removal. 3. Install the
60 percent front seat. 4. Repower the SRS. 5. Check the active restraint system for correct
operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8234
Seat Belt Tensioner: Service and Repair Safety Belt Pretensioner Disposal
Deployed
SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED
1. WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses
when repairing an air bag equipped vehicle
and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never
probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag
deployment and could result in personal injury.
Dispose of the deployed safety belt pretensioner in the same manner as any other part to be
scrapped.
Inoperative
SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, INOPERATIVE
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep
fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an
accidental deployment.
NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have
been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and
safety belt retractor pretensioners must be treated the same as any inoperative live safety belt
buckle pretensioner or safety belt retractor pretensioner being returned.
1. Depower the system. 2. Remove the inoperative safety belt buckle pretensioner or safety belt
retractor pretensioner from the vehicle. 3. Package and return the inoperative safety belt buckle
pretensioner or safety belt retractor pretensioner to Ford Motor Company.
Scrapped Vehicle
SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, SCRAPPED VEHICLE
Remote Deployment
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet)
away to ensure personal safety. Due to the loud report which occurs when the safety belt
pretensioner is deployed, hearing protection is required.
- Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that
moveable parts contact the support surface, as the forces of the deploying pretensioner can cause
it to ricochet and cause personal injury.
All vehicles 1. Depower the system. 2. Remove the safety belt buckle pretensioner assembly from
the vehicle.
Safety belt buckle pretensioner without a hard-wired electrical connector 3. Cut and remove the
safety belt buckle pretensioner electrical connector from the main seat wire harness, leaving about
four inches of extra wire. 4. Attach the electrical connector to the safety belt buckle pretensioner.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Safety Belt Buckle and Pretensioner - 40 Percent Seat > Page 8235
5. Strip the wires near the electrical connector.
6. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of
each wire to the safety belt buckle pretensioner
wires.
7. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area
so that moveable parts do not contact the support
surface.
8. Remain at least 6.1 meters (20 feet) away from the safety belt buckle pretensioner assembly.
9. Deploy the safety belt buckle pretensioner by touching the other ends of the two wires to the
terminals of a 12-volt battery.
10. To allow for cooling, wait at least ten minutes before approaching the deployed safety belt
buckle pretensioner. 11. Dispose of the deployed safety belt buckle pretensioner in the same
manner as any other part to be scrapped.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Description and Operation
Seat Belt Warning Timer: Description and Operation
Warning System - Driver Safety Belt
The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and
chime. The warning indicator and chime are reminders to fasten the safety belt.
- If the driver safety belt is not buckled before the ignition key is turned to ON, the safety belt
warning light illuminates for one to two minutes and the warning chime sounds for four to eight
seconds.
- If the driver side safety belt is buckled while the indicator light is illuminated and the warning
chime is sounding, the safety belt warning light and warning chime turn off.
- If the safety belt is buckled before the key is turned to the ON position, the warning indicator will
come on for four to eight seconds with no chime.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 8242
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 8243
Seat Sensor/Switch: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is mounted to a bracket attached to the inboard side of the seat
track. The seat track position sensor informs the restraints control module (RCM) of the driver seat
position. The RCM uses this information in determining the deployment rate of the dual-stage driver
air bag module.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 8244
Seat Sensor/Switch: Service and Repair
SEAT POSITION SENSOR
Removal
WARNING:
- Always wear safety glasses when repairing a supplemental restraint system (SRS) vehicle and
when handling an airbag 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
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Before removing the seat, position it to access the seat position sensor.
1. Position the seat to allow access to the fasteners. 2. Depower the system. 3. Remove the 40
percent driver front seat.
4. CAUTION: Make sure to remove all metal chips from the seat position sensor and the
surrounding areas after drilling out the rivet.
Remove the seat position sensor. 1
Disconnect the seat position sensor electrical connector.
2 Drill out the rivet.
3 Remove the seat position sensor.
Installation
1. CAUTION: Make sure to remove all metal chips from the seat position sensor and surrounding
areas after drilling out rivet.
Install the seat position sensor. 1
Position the seat position sensor to the seat, engaging the tab to the seat bracket.
2 Install the rivet.
3 Connect the seat position sensor electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 8245
2. Install the 40 percent driver front seat. 3. Repower the system. 4. Check the active restraint
system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8251
Impact Sensor: Locations Safety Canopy Sensor
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8252
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8253
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8254
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor > Page 8257
Impact Sensor: Diagrams Safety Canopy Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor > Page 8258
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Page 8259
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In
addition, make sure the area of the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
For these vehicles, the SRS uses up to eight sensors. Within the RCM there can be up to three
safing sensors which are not separately serviced. The RCM will always have at least one safing
sensor for front impact. Two more safing sensors are used if the vehicle is equipped with safety
canopy modules. The RCM is mounted to the center tunnel beneath the console or bench seat. All
vehicles will have a front impact severity sensor that is located in the front-center of the vehicle,
mounted near the bottom of the hood latch support bracket. If the vehicle is equipped with safety
canopy modules, there are four additional side impact sensors external to the RCM. One front row
side impact sensor is located behind each of the front door interior trim panels. One second row
side impact sensor is located at the base of each C-pillar. Mounting orientation is critical for correct
operation of all impact and rollover sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Side Impact Sensor - Second Row
Impact Sensor: Service and Repair Side Impact Sensor - Second Row
SIDE IMPACT SENSOR - SECOND ROW
Removal
WARNING:
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The driver side is shown, the passenger side is similar.
- 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. Depower the system. 2. Remove the rear door scuff plate.
3. Separate the rear quarter trim panel.
1 Remove the safety belt anchor.
2 Pull out at the front of the rear quarter trim panel, releasing the retaining clips, allowing access to
the side impact sensor.
4. Remove the side impact sensor.
1 Remove the bolt.
2 Disconnect and remove the side impact sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Side Impact Sensor - Second Row > Page 8262
1. Make sure the second row side impact sensor tabs are aligned to the bracket.
2. Install the second row side impact sensor with bracket.
1 Align and insert the second row side impact sensor bracket locator pin to the opening in the
quarter panel sheet metal.
2 Install the bolt.
3 Connect the electrical connector.
3. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Install the rear quarter trim panel. 1
Align the rear quarter trim panel and push in, seating the retaining clips.
2 Install the safety belt anchor.
4. Install the rear door scuff plate. 5. Repower the system. 6. Check the active restraint system for
correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Side Impact Sensor - Second Row > Page 8263
Impact Sensor: Service and Repair Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
Removal
WARNING:
- Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. Depower the system.
2. Remove the pin-type retainers and lower the front lower splash shield to access the front impact
severity sensor.
3. NOTE: The front impact severity sensor is mounted on the bottom of the hood latch support
bracket.
Remove the front impact severity sensor. 1
Remove the nut.
2 Disconnect and remove the front impact severity sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Side Impact Sensor - Second Row > Page 8264
1. CAUTION: If the hood latch support bracket or weld stud are damaged in any way that would
affect the way the front impact severity
sensor mounts to its original manufactured position, a new hood latch support bracket must be
installed.
NOTE: Make sure the hood latch support bracket and front impact severity sensor mating surfaces
are clean and debris free.
Position the front impact severity sensor. 1
Position the front impact severity sensor onto the hood latch support bracket stud.
2 While sliding the front impact severity sensor onto the stud, align the locator tabs to the hood
latch support bracket alignment holes.
2. Install the front impact severity sensor.
1 With the front impact severity sensor sitting flat up against the hood latch support bracket, install
the nut.
2 Connect the front impact severity sensor.
3. Position the front lower splash shield and install the pin-type retainers. 4. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Side Impact Sensor - Second Row > Page 8265
Impact Sensor: Service and Repair Side Impact Sensor - Front Row
SIDE IMPACT SENSOR - FRONT ROW
Removal
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON.
This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- The driver side is shown, the passenger side is similar.
- 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. Depower the system. 2. Remove the front interior door trim panel on the side with the affected
side impact sensor.
3. Separate the weathershield enough to access the side impact sensor.
4. Remove the side impact sensor.
1 Remove the bolt.
2 Disconnect the electrical connector.
3 Remove the side impact sensor.
Installation
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Side Impact Sensor - Second Row > Page 8266
1. CAUTION: Always replace the J-clip retaining nut whenever installing a side impact sensor.
Align the locator tabs to the openings in the door.
2. CAUTION:
- The ground wire must be placed between the bolt head and the sensor. Never position the ground
wire between the J-clip retaining nut and the sensor.
- Always replace the J-clip retaining nut whenever installing a side impact sensor.
Install the side impact sensor. 1
Connect the electrical connector.
2 With the locator tabs aligned to the openings in the door, position the side impact sensor to the
door.
3 Position the ground wire between the bolt head and the sensor.
4 Install the bolt.
3. Position back the weathershield. 4. Install the front interior door trim panel on the side with the
affected side impact sensor. 5. Repower the system.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver > Page 8272
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Page 8273
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the supplemental restraint system (SRS), the driver and front outboard passenger safety
belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches indicate
to the restraints control module (RCM) whether the safety belts are connected or disconnected.
The RCM uses this information in determining the deployment rate of the dual-stage driver and
passenger air bag modules.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 8277
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 8278
Seat Sensor/Switch: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is mounted to a bracket attached to the inboard side of the seat
track. The seat track position sensor informs the restraints control module (RCM) of the driver seat
position. The RCM uses this information in determining the deployment rate of the dual-stage driver
air bag module.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 8279
Seat Sensor/Switch: Service and Repair
SEAT POSITION SENSOR
Removal
WARNING:
- Always wear safety glasses when repairing a supplemental restraint system (SRS) vehicle and
when handling an airbag 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
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Before removing the seat, position it to access the seat position sensor.
1. Position the seat to allow access to the fasteners. 2. Depower the system. 3. Remove the 40
percent driver front seat.
4. CAUTION: Make sure to remove all metal chips from the seat position sensor and the
surrounding areas after drilling out the rivet.
Remove the seat position sensor. 1
Disconnect the seat position sensor electrical connector.
2 Drill out the rivet.
3 Remove the seat position sensor.
Installation
1. CAUTION: Make sure to remove all metal chips from the seat position sensor and surrounding
areas after drilling out rivet.
Install the seat position sensor. 1
Position the seat position sensor to the seat, engaging the tab to the seat bracket.
2 Install the rivet.
3 Connect the seat position sensor electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 8280
2. Install the 40 percent driver front seat. 3. Repower the system. 4. Check the active restraint
system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8286
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8287
Accessory Delay Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8288
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Amplifier > Component Information >
Locations
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Amplifier > Component Information >
Locations > Page 8293
Antenna Amplifier: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component
Information > Service and Repair
Antenna, Navigation: Service and Repair
GLOBAL POSITIONING SYSTEM (GPS) ANTENNA
Removal and Installation
1. Disconnect the battery. 2. Remove the audio unit. 3. Remove the glove compartment.
4. Remove the GPS antenna.
- Disconnect the electrical connector.
- Remove the bolt.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Lead-In Cable - Front
Antenna Cable: Service and Repair Antenna Lead-In Cable - Front
ANTENNA LEAD-IN CABLE - FRONT
Removal and Installation
1. Remove the 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 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Lead-In Cable - Front > Page 8302
5. NOTE: The antenna is an integral part of the wiring harness and cannot be replaced separately
from the harness. Cut the ends off of the old
antenna cable and tape the remainder to the wiring harness to prevent noise.
Remove the ground plate and remove the antenna cable ends.
6. NOTE: When installing the new cable, tape or wire-tie the new cable to the wiring harness to
prevent noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Lead-In Cable - Front > Page 8303
Antenna Cable: Service and Repair Antenna Lead-In Cable - Rear
ANTENNA LEAD-IN CABLE - REAR
Removal and Installation
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.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Lead-In Cable - Front > Page 8304
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.
8. Remove the antenna rear lead-in cable bolt.
9. 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.
Remove the ground plate and remove the antenna cable ends.
10. NOTE: When installing the new cable, tape or wire tie the new cable to the wiring harness to
prevent noise.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 8309
Alarm System Transponder: Service and Repair
PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER
Removal and Installation
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 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, remove the tilt wheel handle.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 8310
5. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
6. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the bolts.
2 Remove the instrument panel steering column opening cover reinforcement.
7. Disconnect the passive anti-theft system (PATS) transceiver electrical connector.
8. Remove the PATS transceiver.
1 Remove the PATS transceiver retaining screw.
2 Remove the PATS transceiver.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 8311
9. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
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 8317
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 5 (2005))
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 8318
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 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8319
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8320
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming
Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad Code Programming
REMOTE KEYLESS ENTRY KEYPAD CODE PROGRAMMING
1. Enter the permanent factory remote keyless entry (RKE) keypad code. 2. Press the 1/2 button
within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2
seconds after activation erases
the stored customer code. The door locks will lock, then unlock, confirming the code is erased. The
existing code does not need to be erased to program a new code.
3. Within 5 seconds, enter the new 5-digit RKE keypad code. The doors lock and unlock to confirm
the new code is programmed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page
8323
Keyless Entry Key-Pad: Service and Repair Autolock and Horn Chirp Programming
AUTOLOCK AND HORN CHIRP PROGRAMMING
1. Close all the doors. 2. Confirm that the ignition switch is in the OFF position. 3. Turn the ignition
switch from OFF to RUN.
4. NOTE: Steps 4 through 8 must be carried out within 30 seconds.
Press the power door lock UNLOCK button 3 times.
5. Turn the ignition switch from RUN to OFF. 6. Press the power door lock UNLOCK button 3
times. 7. Turn the ignition switch from OFF to RUN. 8. Verify that the horn chirps. This indicates the
system is in the enable/disable mode is ready to accept program changes. 9. Press the power door
lock UNLOCK button one time to toggle the autolock/relock feature OFF.
10. Press the power door lock LOCK button once to enter the command. 11. Verify that the horn
chirps one time. There should only be one chirp indicating that autolock/relock feature has been
disabled. If one chirp is
heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled.
Return to Step 9.
12. Turn the ignition switch to the OFF position to exit the enable/disable mode. 13. Exit the vehicle
and verify that the horn chirps once to indicate that a feature has been changed and that
autolock/relock has been disabled.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page
8324
Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad
REMOTE KEYLESS ENTRY KEYPAD
Removal and Installation
1. Remove the exterior mirror.
2. Disconnect the electrical connector. 3. Remove the front door window glass.
4. CAUTION: Damage to the base moulding may occur during the removal procedure.
Remove the front door window base molding.
5. Remove the remote keyless entry (RKE) keypad. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Application and ID
Keyless Entry Module: Application and ID
RKE TRANSMITTER/RKE KEYPAD
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair
Keyless Entry Transmitter: Service and Repair
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING
NOTE:
- All remote keyless entry (RKE) transmitters must be programmed at the same time.
- Programming (or reprogramming) of the RKE transmitters can be accomplished using a
diagnostic tool or by carrying out the following steps:
1. The vehicle must be electronically unlocked before entering program mode using the door lock
control switch while the driver door is open. 2. Turn the ignition switch from the OFF to the RUN
position 8 times within 10 seconds, with the eighth turn ending in RUN. If the module has
successfully entered program mode, it will lock and then unlock all doors.
3. Within 20 seconds, press any button on a RKE transmitter, and the doors will lock and then
unlock to confirm that each RKE transmitter has been
programmed. Repeat this step for each RKE transmitter.
4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the
button again. If the door locks still fail to respond,
refer to Inspection and Verification. (Make sure that no more than the maximum number of RKE
transmitters are attempted to be programmed.) See: Body and Frame/Locks/Power Locks/Testing
and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification
5. Exiting the programming mode is accomplished if one of the following occurs:
- The key transitions to the OFF position.
- 20 seconds have passed since entering programming mode or since the last RKE transmitter was
programmed.
- The maximum number (6) of RKE transmitters have been programmed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for Parking
Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC
C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for Parking
Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 8340
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker
Inop./DTC C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page
8346
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 8347
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 8348
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 8349
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Removal and Installation
All vehicles 1. Remove the LH quarter trim panel.
Navigator
2. Remove the parking aid module.
- Disconnect the electrical connector.
- Remove the screw.
Expedition
3. Remove the parking aid module.
- Disconnect the electrical connectors.
- Remove the screws.
All vehicles 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-6-4 > Apr
> 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE PROCEDURE
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an
audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when
obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-6-4 > Apr
> 05 > Instruments - False Parking Aid Warnings > Page 8358
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four parking aid module parameter identification displays (PIDs) for distance
information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-6-4 > Apr
> 05 > Instruments - False Parking Aid Warnings > Page 8359
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select The Appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-6-4 > Apr
> 05 > Instruments - False Parking Aid Warnings > Page 8360
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-6-4 > Apr
> 05 > Instruments - False Parking Aid Warnings > Page 8361
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE PROCEDURE
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an
audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when
obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8367
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four parking aid module parameter identification displays (PIDs) for distance
information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8368
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select The Appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8369
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8370
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Parking Assist Distance Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Parking Assist Distance Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page
8376
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Parking Assist Distance Sensor: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page
8382
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Outer/Inner Left
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Outer/Inner Left > Page 8385
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations > Outer/Inner Left > Page 8386
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 8389
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 8390
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 8391
Parking Assist Distance Sensor: Diagrams Parking Aid Ultrasonic Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Page 8392
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
Removal and Installation
All vehicles 1. Remove the rear bumper cover.
2. Remove the nuts and the foam absorber from the bumper cover.
Navigator
3. Remove the 2 ultrasonic sensors.
1 Disconnect the electrical connectors.
2 Release the locking tabs.
3 Remove the ultrasonic sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Page 8393
4. Remove the radar sensor.
1 Disconnect the electrical connector.
2 Remove the fasteners.
3 Remove the radar sensor.
Expedition 5. Remove the ultrasonic sensor(s).
1 Disconnect the electrical connector.
2 Release the locking tabs.
3 Remove the ultrasonic sensors.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Page 8394
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 >
Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Warning Indicator: Customer Interest Parking Assist System - Speaker Inop./DTC
C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 >
Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 8403
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Warning Indicator: All Technical Service Bulletins Parking Assist System - Speaker
Inop./DTC C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 8409
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Parking Assist Warning Indicator: > 04-26-23 > Dec > 04 > Steering - Steering Column Creak/Pop/Tick Noise
Steering Shaft: All Technical Service Bulletins Steering - Steering Column Creak/Pop/Tick Noise
TSB 04-26-23
12/31/04
CLUNK, POP, CREAK OR TICK NOISE FROM STEERING COLUMN
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 04-16-14 to update the Service Procedure and affected model years.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 10/18/2004 may exhibit a clunk,
pop, creak, or tick noise coming from the steering column. The noise may occur during
acceleration, deceleration and/or while going over bumps, and is most noticeable after the vehicle
is warmed up. The tick noise may occur when rapidly and repeatedly turning the steering wheel to
the left or right.
ACTION For a clunk, pop or creak condition, it may be necessary to replace the lower intermediate
steering shaft. For a tick condition, inspect the upper-to-lower intermediate shaft union. Refer to the
correct Service Procedure based on symptom.
SERVICE PROCEDURE - Clunk, Pop Or Creak
NOTE
DO NOT ATTEMPT TO ADD GREASE TO THE INTERMEDIATE SHAFT TO RESOLVE THE
CONDITION.
NOTE
BE SURE THE VEHICLE IS AT FULL OPERATING TEMPERATURE DURING VERIFICATION.
1. Road test the vehicle to verify the condition.
2. If condition is verified, replace the lower intermediate steering shaft following the service
procedure in Workshop Manual Section 211-04. Torque the upper-to-lower intermediate shaft bolt
to 40 lb-ft (55 N.m).
NOTE
CHECK BUILD DATE CODES ON THE REPLACEMENT SHAFT PRIOR TO INSTALLATION.
ONLY INSTALL PARTS BUILT AFTER DATE CODE 0410080X (OCTOBER 8, 2004). THE LAST
TWO DIGITS OF THE DATE CODE (0X) INDICATE THE SHIFT IN WHICH THE PARTS WERE
BUILT (X CAN EQUAL 1, 2, OR 3).
SERVICE PROCEDURE - Tick
1. Turn steering wheel rapidly and repeatedly to the left or right while parked to verify the condition.
2. If the condition is verified, inspect the upper-to-lower intermediate shaft union and re-torque the
bolt to 40 lb-ft (55 N.m).
3. If the noise is still present, follow normal diagnostics.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Parking Assist Warning Indicator: > 04-26-23 > Dec > 04 > Steering - Steering Column Creak/Pop/Tick Noise > Page 8415
Labor Operation Claiming Chart
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3B676 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Parking Assist Warning Indicator: > 04-26-23 > Dec > 04 > Steering - Steering Column Creak/Pop/Tick Noise > Page 8421
Labor Operation Claiming Chart
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3B676 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Page 8422
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 8426
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 8427
Driver/Vehicle Information Display: Description and Operation
INFORMATION AND MESSAGE CENTER
The message center display is a green vacuum fluorescent, fixed format display. The message
center is a 2-line display integrated into the center of the instrument cluster and is controlled by the
message center switches. Refer to the Owner's Literature for operating instructions.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview
Principles of Operation
PRINCIPLES OF OPERATION
The message center is a vacuum fluorescent display, part of the instrument cluster. The message
center electronic functions use both hardwired, and controller area network (CAN) to transmit and
receive information. As a technician, it is very important to understand:
- where the input (command) originates.
- all the information (messages) necessary in order for a feature to operate.
- which module(s) receive(s) the input or command message.
- if the module that received the input (message) controls the output of the feature, or if it outputs a
message over the CAN to another module.
- which module controls the output of the feature.
The message center provides the following features:
- information displays
- setup displays
- warning messages
- system check messages
The message center information can be selected through a set of 3 buttons:
- INFO
- SETUP
- RESET
Information Displays The information displays are non-timed modes. The selected mode remains
on until the driver depresses a message center button to change the mode or it is overridden by
another mode. The information display modes are:
- odometer
- trip odometer
- compass
- distance to empty
- average fuel economy
Setup Displays The setup displays are timed modes and terminate after a finite interval. The setup
display modes are:
- system check
- English/metric units
- power liftgate on/off (if equipped)
- running board auto in/out (if equipped)
- easy exit seat (if equipped)
- autolamp delay
- language
Warning Messages The warning messages are single cycle, non-resettable and repetitive warning
messages. The single cycle warning messages are:
- CHECK SUSPENSION
- CHECK COMPASS MODULE
- NO RESPONSE COMPASS
- ENGINE TEMP DATA
- COMPASS DATA ERROR
- DOOR SENSOR DATA ERROR
- CHARGING SYSTEM DATA ERROR
- CHECK PARK ASSIST
- CHECK FUEL CAP
- LOW WASHER FLUID LEVEL
The single cycle warning messages display once whenever the ignition switch is turned to ON or a
fault occurs in a system and can be cleared by pressing the RESET button.
The repetitive warning messages are:
- LOW BRAKE FLUID LEVEL
- CHECK CHARGING SYSTEM
- LOW FUEL LEVEL
- LOW OIL PRESSURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8430
- CHECK ENGINE TEMPERATURE
- TEMPORARY 4x4 HIGH
- CHECK ADV/TRAC
The repetitive warning messages are displayed at a fixed interval whenever the ignition switch is
turned ON or is in the ACC position. To remove a repetitive warning message, press the RESET
button. The message only reoccurs after 10 minutes or until the warning condition is corrected.
The non-resettable warning messages display whenever the ignition switch is turned to ON and a
fault occurs in a system. The fault must be corrected to clear the non-resettable warning
messages.
The non-resettable warning messages are:
- DOOR AJAR
- STOP ENGINE SAFELY
- REDUCED ENGINE POWER
- ENGINE FAILSAFE MODE
- PARK ASSIST ON/OFF
- TRAIN LF TIRE
- TRAIN LR TIRE
- TRAIN RF TIRE
- TRAIN RR TIRE
- TRAIN SPARE TIRE
- TIRE TRAINING MODE COMPLETE
- TIRES NOT TRAINED
- PARK BRAKE ENGAGED
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link
connector (DLC) and select the vehicle to be tested from the
diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: Check that the program card is correctly installed.
- Check the connections to the vehicle.
- Check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
- CAN circuit fault; all electronic control units no response/not equipped, refer to Information Bus
(Module Communications Network).
- No response/not equipped for the instrument cluster, refer to Instrument Cluster.
- System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the
continuous DTCs, and carry out self-test diagnostics for the instrument cluster.
7. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic
Trouble Code (DTC) Index. See: Diagnostic Trouble
Code Descriptions
8. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8431
B1209 / U2013
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8432
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8433
Symptom Chart (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8434
Symptom Chart (Part 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8435
Symptom Chart (Part 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8436
Symptom Chart (Part 5)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8437
Driver/Vehicle Information Display: Pinpoint Tests
Test A: The Message Center Is Not Operating Correctly
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY
A1
Test B: The Compass Is Inoperative
PINPOINT TEST B: THE COMPASS IS INOPERATIVE
B1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8438
B1-B3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8439
B3 Continued
Test C: The Compass Is Inaccurate
PINPOINT TEST C: THE COMPASS IS INACCURATE
C1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8440
C2-C3
Test D: The Message Center Switch Does Not Operate Correctly
PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
D1-D3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8441
D3-D5
Test E: The Power Liftgate Display Is Inoperative
PINPOINT TEST E: THE POWER LIFTGATE DISPLAY IS INOPERATIVE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8442
E1-E3
Test F: The Power Running Boards Display Is Inoperative
PINPOINT TEST F: THE POWER RUNNING BOARDS DISPLAY IS INOPERATIVE
F1-F3
Test G: The Park Assist On/Off Display Is Inoperative
PINPOINT TEST G: THE PARK ASSIST ON/OFF DISPLAY IS INOPERATIVE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8443
G1
G2-G3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Page 8444
Driver/Vehicle Information Display: Service and Repair
MESSAGE CENTER SWITCH
Removal and Installation
1. Remove the instrument cluster finish panel.
2. NOTE: Navigator shown, Expedition similar.
Press the tabs and remove the message center switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Page 8445
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Specifications
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Specifications > Page 8450
Television / Monitor: Description and Operation
VIDEO SYSTEM
The video system consists of the following components:
- an overhead assembly containing the video display screen and the digital versatile disc (DVD)
player
- remote control
The components of the assembly are not repairable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Diagrams > Page 8454
DVD Player: Service and Repair
DIGITAL VERSATILE DISC (DVD) PLAYER
Removal and Installation
CAUTION: When removing the DVD unit do not pull on the display. This may cause damage to the
unit and void the warranty.
1. Disconnect the battery ground cable.
2. Open the video display door.
3. Remove the screws.
4. NOTE: The DVD assembly must be supported while disengaging the clips.
Remove the DVD assembly. 1
Close the video display door.
2 Disengage the clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Diagrams > Page 8455
5. Disconnect the electrical connector.
6. Remove the DVD player.
1 Remove the four screws.
2 Disconnect the electrical connector.
7. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Description and Operation
Garage Door Opener Transmitter: Description and Operation
UNIVERSAL TRANSMITTER
The HomeLink(R) universal transmitter provides a convenient way to substitute up to 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.
- 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 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
VISUAL INSPECTION CHART
Mechanical Damaged universal transmitter
- Damaged receiver
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8461
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8462
Garage Door Opener Transmitter: Pinpoint Tests
PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 8463
Garage Door Opener Transmitter: Service and Repair
PROGRAMMING
WARNING: A garage door opening system that cannot stop or reverse itself after detecting an
object in its path does not meet current federal safety standards. To decrease the risk of serious
injury or death, do not use this HomeLink(R) transmitter with a door opening system that lacks stop
and reverse features as required by federal standards. This includes any garage door opening
system manufactured before April 1, 1982. For more information, call HomeLink(R) customer
assistance at 1-800-355-3515.
1. CAUTION: During this procedure, the system that you are programming will be made to operate.
Make sure that people or objects are
clear of the garage door or gate being programmed.
Verify the hand-held transmitter is operative.
2. Prepare for programming the universal transmitter by erasing all three channels by holding down
the two outside buttons until the red light begins
to flash (20-30 seconds). Release both buttons.
3. Select one of the three universal transmitter channels to be programmed by pressing the desired
button. 4. Hold the end of the hand-held transmitter 25-51mm (1-2 in) from the front surface of the
universal transmitter so that the red light can still be
seen.
5. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after
two seconds, which may not be long enough to
program the universal transmitter. If programming this type of hand-held transmitter, continue to
hold the button on the universal transmitter while re-pressing the hand-held transmitter button
every two seconds (Canada only).
Use both hands to press the hand-held transmitter button and the desired button on the universal
transmitter. Do not release either button.
6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and
then rapidly. Release both buttons when the rapid
flashing begins. The universal transmitter has successfully learned the new frequency signal and
can be used in place of the hand-held transmitter(s).
7. NOTE: If the hand-held transmitter appears to program the universal transmitter but does not
open the garage door, the garage door opener may
have a "code protected" or "rolling code" feature.
To operate, simply press the appropriate button on the universal transmitter. The red light is on
while the signal is being transmitted.
Training a Garage Door Opener Equipped With "Rolling Codes"
1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener
receiver to recognize the universal transmitter.
1 Remove the cover panel from the garage door opener receiver.
2 Locate the training button on the garage door opener receiver. Location and color of the button
may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual
or call HomeLink(R) customer assistance at 1-800-355-3515.
3 Press the training button on the garage door opener receiver for 1-2 seconds.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 8464
4 Press the programmed universal transmitter button for as long as the universal transmitter red
light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal
transmitter is trained to the receiver.
5 The garage door opener should recognize the universal transmitter.
Erasing Channels
1. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures
for programming.
To erase all three programmed channels, hold down the two outside buttons until the red light
begins to flash (20-30 seconds). Release both buttons.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8469
Memory Positioning Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8470
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations > Page 8474
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations > Page 8475
Seat Memory Switch: Testing and Inspection
SWITCH - MEMORY SET
Memory Set Switch
Remove the memory set switch.
Measure the resistance between the indicated terminals while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to
the calling pinpoint test.
NOTE: Refer to multimeter user's manual for testing diodes.
To check the memory set switch LED, connect the positive meter lead to terminal 7 and the
negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, install a new switch; otherwise, return to the
calling pinpoint test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit
Navigation Module: Diagrams Audio/Navigation Control Unit
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit > Page 8482
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit > Page 8483
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit > Page 8484
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit > Page 8485
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit > Page 8486
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Audio/Navigation Control Unit > Page 8487
Navigation Module: Diagrams Navigation Module
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams > Page 8488
Navigation Module: Service and Repair
NAVIGATION SYSTEM MODULE
Removal and Installation
1. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
NOTE: Prior to removal of the navigation system module, it is necessary to remove the digital
versatile disc (DVD) from the navigation system module and store it in the customer case.
Disconnect the battery.
2. Remove the lower LH and RH panels from the front floor console.
3. Remove the navigation system module.
- Remove the electrical connectors.
- Remove the screws.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 8493
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor >
Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations > Page 8500
Pedal Positioning Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 8503
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 8504
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 8505
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Subwoofer Amplifier
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Subwoofer Amplifier > Page 8511
Amplifier: Diagrams Radio Amplifier
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Service and Repair > Subwoofer Amplifier
Amplifier: Service and Repair Subwoofer Amplifier
SUBWOOFER AMPLIFIER
Removal and Installation
1. Disconnect the battery. 2. Remove the rear quarter trim.
3. Remove the subwoofer amplifier.
1 Disconnect the electrical connectors.
2 Remove the screws.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Service and Repair > Subwoofer Amplifier > Page 8514
Amplifier: Service and Repair Audio Amplifier
AUDIO AMPLIFIER
Removal and Installation
1. Disconnect the battery.
2. NOTE: RH side is shown, LH side is similar.
Remove the LH and RH front floor console side finish panels.
3. Remove the bolts and audio amplifier/navigation DVD assembly.
- Disconnect the electrical connectors.
4. Remove the 4 bolts and the audio amplifier. 5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > CD Changer > Component Information > Diagrams > Page 8519
CD Changer: Service and Repair
COMPACT DISC (CD) CHANGER
Removal and Installation
1. Disconnect the battery.
2. Remove the mat at the bottom 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 the bracket.
4. Disconnect the electrical connector.
5. Remove the screws. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Radio
Radio/Stereo: Diagrams Radio
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Radio > Page 8524
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Diagrams > Radio > Page 8525
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Diagrams
Remote Control: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Diagrams > Page 8529
Remote Control: Service and Repair
REAR AUXILIARY AUDIO CONTROLS
Removal and Installation
1. Disconnect the battery.
2. Remove the screws under the armrest cover.
3. Open the rear cup holder and remove the bolt(s).
1 Navigator
2 Expedition
4. Detach the pin-type retainers.
NOTE: Standard audio is shown, others are similar.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Diagrams > Page 8530
5. Remove the rear auxiliary audio controls unit.
1 Remove the screws.
2 Disconnect the electrical connector.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Specifications
Torque Specifications
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker
Speaker: Diagrams Speaker
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker > Page 8536
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker > Page 8537
Speaker: Diagrams Tweeter
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker > Page 8538
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 8539
Speaker: Description and Operation
SPEAKERS
The speaker system consists of the following components:
- subwoofer
- speakers
On all vehicles:
- The rear speakers are located behind the rear door trim panels.
- The front speakers are located behind the front door trim panels.
- The subwoofer is located behind the LH quarter trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Front Door Tweeter Speaker
Speaker: Service and Repair Front Door Tweeter Speaker
FRONT DOOR TWEETER SPEAKER
Removal and Installation
1. Remove the door trim panel.
2. Disconnect the electrical connector and remove the bolts. 3. To install, reverse the removal
procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Front Door Tweeter Speaker > Page 8542
Speaker: Service and Repair Subwoofer Speaker
SUBWOOFER SPEAKER
Removal and Installation
1. Remove the rear quarter trim panel.
2. Remove liftgate module bolt (if equipped) and remove liftgate module.
NOTE: Early build is shown, late build is similar
3. Remove the subwoofer assembly.
1 Disconnect the subwoofer amplifier electrical connector.
2 Remove the bolts.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Front Door Tweeter Speaker > Page 8543
Speaker: Service and Repair Door Speaker
DOOR SPEAKER
Removal and Installation
1. Remove the door trim panels.
2. Remove the bolts.
3. Disconnect the electrical connector. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8549
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8550
Accessory Delay Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8551
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Application and ID
Keyless Entry Module: Application and ID
RKE TRANSMITTER/RKE KEYPAD
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit
Navigation Module: Diagrams Audio/Navigation Control Unit
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 8560
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 8561
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 8562
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 8563
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 8564
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 8565
Navigation Module: Diagrams Navigation Module
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams > Page 8566
Navigation Module: Service and Repair
NAVIGATION SYSTEM MODULE
Removal and Installation
1. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
NOTE: Prior to removal of the navigation system module, it is necessary to remove the digital
versatile disc (DVD) from the navigation system module and store it in the customer case.
Disconnect the battery.
2. Remove the lower LH and RH panels from the front floor console.
3. Remove the navigation system module.
- Remove the electrical connectors.
- Remove the screws.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC
C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page
8575
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC
C1742/C1743
Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker
Inop./DTC C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC
C1742/C1743 > Page 8581
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 8582
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 8583
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 8584
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Removal and Installation
All vehicles 1. Remove the LH quarter trim panel.
Navigator
2. Remove the parking aid module.
- Disconnect the electrical connector.
- Remove the screw.
Expedition
3. Remove the parking aid module.
- Disconnect the electrical connectors.
- Remove the screws.
All vehicles 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE PROCEDURE
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an
audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when
obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8594
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four parking aid module parameter identification displays (PIDs) for distance
information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8595
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select The Appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8596
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8597
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE PROCEDURE
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an
audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when
obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8603
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four parking aid module parameter identification displays (PIDs) for distance
information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
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Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8604
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select The Appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8605
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8606
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Outer/Inner Left
View 151-19 (Left Rear)
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Outer/Inner Left > Page 8609
View 151-21 (Right Rear)
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Outer/Inner Left > Page 8610
View 151-21 (Right Rear)
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 8613
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 8614
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor > Page 8615
Parking Assist Distance Sensor: Diagrams Parking Aid Ultrasonic Sensor
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Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8616
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
Removal and Installation
All vehicles 1. Remove the rear bumper cover.
2. Remove the nuts and the foam absorber from the bumper cover.
Navigator
3. Remove the 2 ultrasonic sensors.
1 Disconnect the electrical connectors.
2 Release the locking tabs.
3 Remove the ultrasonic sensors.
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4. Remove the radar sensor.
1 Disconnect the electrical connector.
2 Remove the fasteners.
3 Remove the radar sensor.
Expedition 5. Remove the ultrasonic sensor(s).
1 Disconnect the electrical connector.
2 Release the locking tabs.
3 Remove the ultrasonic sensors.
All vehicles
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8618
6. To install, reverse the removal procedure.
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Sensor > Component Information > Diagrams
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations
View 151-12 (Dash Panel)
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8625
Pedal Positioning Switch: Diagrams
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory > Page 8628
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory > Page 8629
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Testing and Inspection > Adjustable Pedal Switch Without Memory > Page 8630
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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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Component Information > Diagrams > Diagram Information and Instructions > Page 8637
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Component Information > Diagrams > Diagram Information and Instructions > Page 8638
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Component Information > Diagrams > Diagram Information and Instructions > Page 8639
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Component Information > Diagrams > Diagram Information and Instructions > Page 8640
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
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Component Information > Diagrams > Diagram Information and Instructions > Page 8641
Symbols and Wire Color Code Identification
Symbols Part 1
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Component Information > Diagrams > Diagram Information and Instructions > Page 8642
Symbols Part 2
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Component Information > Diagrams > Diagram Information and Instructions > Page 8643
Symbols Part 3
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Component Information > Diagrams > Diagram Information and Instructions > Page 8644
Symbols Part 4
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Component Information > Diagrams > Diagram Information and Instructions > Page 8645
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8646
Trailer Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8647
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8648
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8649
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8650
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8651
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8652
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8653
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8654
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8655
Trailer Connector: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8656
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8657
Trailer Connector: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8658
95-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8659
95-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair
Trailer Hitch: Service and Repair
TRAILER HITCH
Removal and Installation
WARNING: Do not permanently remove the trailer hitch. Always reinstall the hitch before delivery
of the vehicle to the customer. Failure to follow this warning could increase the risk of injury in a
rear end collision.
1. Raise and support the vehicle. 2. Remove the trailer hitch rear bumper cover trim panel.
3. Remove the trailer lighting plug cover and disconnect the electrical connector.
4. Remove the trailer lighting plug.
1 Position the plug away from the trailer hitch.
2 Disconnect the electrical connector.
3 Remove the trailer lighting plug.
5. Remove the trailer hitch.
- Remove the eight bolts.
6. NOTE: Do not reuse body support mounting fasteners. New fasteners must be installed for each
fastener that has been removed or loosened.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions
Trailer Lamps: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8667
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8668
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8669
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8670
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8671
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8672
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8673
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8674
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8675
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8676
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8677
Trailer Lamps: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8678
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8679
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8680
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8681
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8682
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8683
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8684
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8685
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8686
Trailer Lamps: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8687
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
VISUAL INSPECTION CHART
Electrical Central junction box (CJB) fuse(s): 10 (20A)
- 13 (10A)
- 29 (30A)
- 6 (10A)
- 2 (10A)
- 106 (30A)
- Circuitry
- Lamps
- Trailer tow battery charge relay
- Trailer tow park lamp relay
- Trailer tow electric brake controller
- CJB
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8690
Trailer Lamps: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Symptom Chart (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8691
Trailer Lamps: Pinpoint Tests
Test X: The Trailer Lamps Are Inoperative
PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE
X1-X2
Test Y: The Individual Trailer Lamp Is Inoperative - RH Trailer Signal/Stoplamp/Hazard Flasher
Lamp
PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER
SIGNAL/STOPLAMP/HAZARD FLASHER LAMP
Y1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8692
Y2-Y3
Test Z: The Individual Trailer Lamp Is Inoperative - LH Trailer Turn Signal/Stoplamp/Hazard
Flasher Lamp
PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER TURN
SIGNAL/STOPLAMP/HAZARD FLASHER LAMP
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8693
Z1-Z2
Z2-Z3
Tests AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps
PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS
AA1-AA2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8694
AA2-AA5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8695
AA5-AA7
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8696
AA8
Tests AB: Trailer Lamps Are Inoperative - Trailer Reversing Lamps
PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING
LAMPS
AB1-AB2
Tests AC: The Trailer Lamps Are ON Continuously
PINPOINT TEST AC: THE TRAILER LAMPS ARE ON CONTINUOUSLY
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8697
AC1
AC1-AC3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8698
AC4
Tests AD: The Trailer Battery Charging Is Inoperative
PINPOINT TEST AD: THE TRAILER BATTERY CHARGING IS INOPERATIVE
AD1-AD2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8699
AD2-AD4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8700
AD4-AD5
Tests AE: The Trailer Electric Brakes Are Inoperative
PINPOINT TEST AE: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE
AE1-AE2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8701
AE2-AE3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8702
AE4-AE5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8703
AE6
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Page 8704
73III Automotive Meter
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 8709
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 8712
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 8715
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 8716
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 8717
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 8721
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 8722
Trailer Towing Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 8723
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8728
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8729
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8730
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8731
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8732
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8733
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8734
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8735
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8736
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8737
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8738
Trailer Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8739
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8740
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8741
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8742
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8743
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8744
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8745
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8746
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8747
Trailer Connector: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8748
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8749
Trailer Connector: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8750
95-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8751
95-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations
Body Control Module: Locations
VEHICLE SECURITY MODULE (VSM)
View 151-17 (RH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations > Page 8757
Body Control Module: Diagrams
VEHICLE SECURITY MODULE (VSM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations > Page 8758
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Removal and Installation
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
- Prior to the removal of the module, it is necessary to upload module configuration information to
the appropriate diagnostic equipment. This information needs to be downloaded into the new
module once installed.
1. Disconnect the battery.
2. NOTE: The module is accessed with the seat fully in the UP position.
Slide the driver seat module forward to remove it from the bracket.
3. Disconnect the connectors and remove the DSM.
4. CAUTION: Once the module is installed it is necessary to download the module configuration
information from the diagnostic tool into
the new module.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM) > Page 8761
Body Control Module: Service and Repair Vehicle Security Module
VEHICLE SECURITY MODULE
Removal
1. NOTE: Prior to removal of the vehicle security module, it is necessary to upload the module
configuration information to a diagnostic tool. This
information needs to be downloaded into the new module once installed.
Disconnect the battery.
2. Remove the pin-type retainer and the RH A-pillar lower trim panel.
3. Disconnect the 3 vehicle security module electrical connectors. 4. Remove the 2 screws and the
vehicle security module.
Installation
1. Position the vehicle security module and install the 2 screws. 2. Connect the 3 vehicle security
module electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type
retainer. 4. Connect the battery. 5. Reconfigure the VSM module. 6. Train the tire pressure
sensors. 7. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Locations > Running Board Motor Assembly, Left
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Locations > Running Board Motor Assembly, Left > Page 8767
View 151-17 (RH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Running Board Motor Assembly, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Running Board Motor Assembly, Left > Page 8770
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair
Front Bumper Cover / Fascia: Service and Repair
FRONT BUMPER COVER
Removal and Installation
All vehicles
1. Remove the lower air deflector.
- Remove the pin-type retainers.
2. Remove the front bumper cover lower pin-type retainers.
3. Remove the front fender splash shield screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Page 8776
4. Remove the front fender to front bumper cover bolts.
Expedition
5. Disconnect the fog lamp electrical connectors.
6. Remove the upper air deflector.
1 Remove the pin-type retainers.
2 Remove the upper air deflector.
7. Remove the two torx bolts.
8. Release the front bumper cover clips and remove the front bumper cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Page 8777
Navigator
9. Disconnect the fog lamp electrical connectors.
10. Release the front bumper cover clips and remove the front bumper.
All vehicles
11. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair
Rear Bumper Cover / Fascia: Service and Repair
REAR BUMPER COVER
Removal and Installation
NOTE: Navigator shown, Expedition similar.
1. Remove the rear fender splash shield bolts.
2. Remove the rear bumper cover nuts and bolts.
3. If equipped, disconnect the reverse parking aid electrical connector.
4. Remove the rear bumper cover lower pin-type retainers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Page 8782
5. Remove the liftgate trim.
- Remove the pin-type retainers.
6. Remove the rear bumper cover.
- Remove the pin-type retainers and bolts.
7. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Remove the windshield wipers. 2. Remove the cowl grille seal.
3. Remove the pin-type retainer and left side cowl trim panel.
- Disconnect the windshield washer tube.
4. Remove the right side cowl trim panel.
1 Disconnect the windshield washer tube.
2 Remove the pin-type retainer.
5. If necessary, adjust the windshield wiper arms. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
EXTERIOR FRONT DOOR HANDLE
Removal and Installation
NOTE: The front door window glass must be completely raised.
1. Remove the front door trim panel. 2. Position the watershield aside.
3. Remove the exterior front door handle.
1 Disconnect the exterior door handle actuating rod.
2 If equipped, disconnect the door lock cylinder rod.
3 Remove the 2 nuts.
4 Push the exterior door handle out from the bottom surface of the handle.
4. NOTE: Make sure the door handle and the front door handle rod is in a relaxed position and that
the front door handle rod is all the way up
before closing the clips.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Interior Handle > System Information > Service and Repair
Front Door Interior Handle: Service and Repair
INTERIOR DOOR HANDLE - REAR
Removal and Installation
1. Remove the front or rear door trim panel.
2. Remove the door handle insulator. 3. Position the watershield aside.
4. Remove the interior door handle.
1 Release the door handle cable from the door carrier.
2 Release the door carrier retaining clip.
3 Position aside the interior door handle.
5. Release the cable from the handle.
6. NOTE: Make sure the interior door handle spring has been realigned before installation of the
door handle. Check for normal operation.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 door striker. 2. Remove the front fender.
3. Loosen the front door hinge-to-body bolts. 4. Adjust the front door alignment to specification.
5. Tighten the front door hinge-to-body bolts. 6. Install the front fender.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 8801
7. Install and adjust the door striker.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 8802
Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Horizontal and Vertical
HINGE ADJUSTMENT - FRONT DOOR, HORIZONTAL AND VERTICAL
1. Remove the door striker.
2. Loosen the front door hinge-to-front door bolts enough to permit movement of the door. 3. Adjust
the front door alignment.
4. Tighten the front door hinge-to-front door bolts.
5. Install and adjust the door striker.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair
Front Door Latch: Service and Repair
FRONT DOOR LATCH
Removal and Installation
1. NOTE: The door glass must be completely raised.
Remove the front door trim panel.
2. Position the watershield aside.
3. If equipped, disconnect the lock cylinder rod.
4. Disconnect the exterior door handle actuating rod.
5. Remove the bolts and position the front door latch aside.
- Discard the bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Page 8806
6. Disconnect the electrical connectors.
7. Release the interior door handle cable and remove the front door latch.
1 Position the cable cover aside.
2 Release the conduit and the interior door handle cable.
8. To install, reverse the removal procedure.
- Transfer parts as necessary.
- If necessary, use multi-purpose grease to lubricate the latch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair
Front Door Panel: Service and Repair
FRONT DOOR TRIM PANEL
Removal and Installation
NOTE: Left front door shown, right front similar.
1. Remove the window control switch plate.
- Use service notch and disconnect the electrical connectors.
2. Remove the door handle bezel.
- Use service notch.
3. CAUTION: To avoid damage to the door trim panel, lift the door trim panel by pulling directly
upward on the armrest to disengage the
panel clips.
Remove the two bolts and three screws, and remove the door trim panel. Remove the finish cover to access the two center screws.
- Disconnect the electrical connectors.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window
Scratched
Front Door Window Glass: Customer Interest Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window
Scratched > Page 8818
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window
Scratched > Page 8819
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window
Scratched > Page 8820
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window
Scratched > Page 8821
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5
> May > 07 > Body - Front Door Window Scratched
Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5
> May > 07 > Body - Front Door Window Scratched > Page 8827
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5
> May > 07 > Body - Front Door Window Scratched > Page 8828
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5
> May > 07 > Body - Front Door Window Scratched > Page 8829
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5
> May > 07 > Body - Front Door Window Scratched > Page 8830
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-19-12 >
Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349
Alternator: All Technical Service Bulletins Charging System - DTC P0340/P0344/P0345/P0349
TSB 06-19-12
10/02/06
DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V
FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer
2007 Explorer Sport Trac
LINCOLN: 2005-2006 Navigator
MERCURY: 2006 Mountaineer
This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and
service parts updated.
ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005
and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT
vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or
P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a
4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning
diode or open phase connection in the generator.
ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the
generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for
performing a generator frequency test using the WDS oscilloscope function.
SERVICE PROCEDURE
NOTE
USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD
INDICATOR OF A FAULTY GENERATOR.
NOTE
ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE.
1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean
and secure.
2. Attach WDS battery cable clamps to battery/battery cables.
3. Turn on WDS.
4. Select the Toolbox Icon, (upper left of WDS screen).
5. Select Oscilloscope and then click OK.
6. Select Channel 1, Auto, Generator Ripple.
7. Select Calculations, Channel 1, Frequency.
8. Select Calculations again.
9. Push the RUN/STOP button. A waveform should display on the screen.
10. Start the vehicle and leave at idle (engine speed less than 800 RPM).
11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc).
12. Examine the frequency reading on WDS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-19-12 >
Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 8836
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-19-12 >
Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 8837
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-19-12 >
Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 8838
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-19-12 >
Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 8839
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8840
Front Door Window Glass: By Symptom
Technical Service Bulletin # 07-10-5 Date: 070528
Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8841
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8842
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8843
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8844
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Technical Service Bulletin # 07-10-5 Date: 070528
Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8845
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8846
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8847
The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And
Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 8848
Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Page 8849
Front Door Window Glass: Service and Repair
FRONT DOOR WINDOW GLASS
Removal and Installation
All vehicles 1. Remove the front door trim panel.
2. Remove the front door weathershield.
Expedition
3. NOTE: Driver side shown, passenger side similar.
Connect the window control switch.
All vehicles 4. Lower the window glass to access the two window glass to regulator bolts.
5. Remove the inside glass weatherstrip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Technical Service Bulletins > Page 8850
6. Remove the front door glass channel bolt and position aside the channel.
7. Remove the window glass to regulator bolts and front door window glass. 8. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Locations > Left Front
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Locations > Left Front > Page 8855
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Left Front
Front Door Window Motor: Diagrams Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Left Front > Page 8858
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Door Window Motor Initialization
Front Door Window Motor: Service and Repair Door Window Motor Initialization
DOOR WINDOW MOTOR INITIALIZATION
CAUTION: Make sure that no obstructions are present in the window system when carrying out this
procedure.
NOTE:
- The LF window motor is in proportional up/down mode until initialized.
- The LF window motor must be reinitialized whenever: the motor is removed from window
regulator drum housing, a new motor is installed, a new window regulator is installed, new window
glass is installed, glass top run removal or installation, or when carrying out any operation in which
grease or lubricants are applied to the window system.
- All LF window components (window glass, window regulator, window motor, and glass top run)
must be installed and tightened to specification before carrying out this procedure.
- If this procedure is only partially completed, the LF window motor will remain un-initialized and
only the proportional up/down functions will operate.
- Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire
procedure is completed.
- Step 7 requires that the master control switch (LF) be held in the UP position until the LF window
motor stalls the window glass into the upper header seal. Step 8 requires that the master control
switch (LF) be momentarily actuated to the DOWN position.
- Step 9 requires that the master control switch (LF) be held in the UP position until the LF window
motor stalls the window glass into the upper header seal and the window carries out its down-up
sequence, indicating successful completion of initialization.
- The key-in-ignition chime can cause the AUTO button to be pressed more or less than six times
due to the distraction of the chime.
1. NOTE: Steps 1 through 6 must be completed within 30 seconds. The entire procedure must be
completed within five minutes.
Start with the ignition key in the OFF position and with the LF door open.
2. Turn the ignition key to the ON position.
3. Press the front window control switch (LF) to the AUTO position six times (AUTO up or AUTO
down). 4. Turn the ignition key to the OFF position and make sure the LF door is open.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Door Window Motor Initialization > Page 8861
5. Press the front window control switch (LF) to the AUTO position six times (AUTO up or AUTO
down). 6. Turn the ignition key to the ON position and close the LF door. The LF window glass will
move down-up-down-up approximately 2-3 mm (0.1
in). This down-up-down-up movement indicates that the LF window motor has entered initialization
mode.
7. Pull and hold the front window control switch (LF) to the UP position until the window glass stalls
into the upper header seal.
8. Momentarily press the front window control switch (LF) to the DOWN position and release. The
window will carry out a one-touch down
operation until the window glass stalls at the bottom of travel stop designed into the window
regulator.
9. Pull and hold the front window control switch (LF) to the UP position. Continue to hold the switch
until after the window glass stalls into the
upper header seal and carries out the down-up movement. This down-up movement approximately
2-3 mm (0.1 in.) indicates that the LF window motor has been successfully initialized.
10. Verify correct operation of the LF window by carrying out a one-touch down, one-touch up,
proportional down, and proportional up. If the
window does not operate correctly, carefully repeat this procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Door Window Motor Initialization > Page 8862
Front Door Window Motor: Service and Repair Front Door Window Regulator Motor
FRONT DOOR WINDOW REGULATOR MOTOR
Removal and Installation
1. Remove the front door trim panel.
2. Position the front door weathershield aside.
3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator
assembly to hold the window regulator assembly
drum in place.
Remove the bolts and the front door window regulator motor. 1
Disconnect the electrical connector.
2 Remove the bolts.
4. To install, reverse the removal procedure.
- Cycle the window glass to make sure the gears engage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
FRONT DOOR WINDOW REGULATOR
Removal and Installation
All vehicles 1. Remove the front door trim panel.
2. Remove the screws and the front door speaker.
- Disconnect the electrical connector.
3. Remove the front door weathershield.
Expedition
4. NOTE: Driver side shown, passenger side similar.
Connect the window control switch.
All vehicles 5. Lower the window glass to access the two window glass-to-regulator bolts.
Expedition
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8866
6. NOTE: Driver side shown, passenger side similar.
Disconnect the window control switch.
All vehicles
7. Remove the window glass-to-regulator bolts and front door window glass.
8. NOTE: Secure the front window glass in the full up position.
Secure the front window glass with tape to the front door frame.
9. Position the interior door handle aside.
1 Remove the cable conduit fitting from the carrier assembly.
2 Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of
the bracket.
3 Remove the cable from the door handle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8867
10. Release the crash sensor harness pin-type retainers.
11. Position the front door window regulator harness aside.
1 Disconnect the electrical connectors.
2 Release the pin-type retainers.
12. Remove the front window regulator.
1 Loosen the two hanger bolts.
2 Remove the front window regulator bolts and front top run channel bolt.
13. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair
EXTERIOR REAR DOOR HANDLE
Removal and Installation
NOTE: The rear door window glass must be completely raised.
1. Remove the rear door trim panel. 2. Position the watershield aside.
3. Remove the childproof door lock cover.
4. Disconnect the exterior door handle actuation rod.
5. Remove the exterior rear door handle.
1 Remove the 2 nuts.
2 Push the exterior door handle out from the bottom surface of the handle.
6. 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.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Interior Handle > System Information > Service and Repair
Rear Door Interior Handle: Service and Repair
INTERIOR DOOR HANDLE - REAR
Removal and Installation
1. Remove the front or rear door trim panel.
2. Remove the door handle insulator. 3. Position the watershield aside.
4. Remove the interior door handle.
1 Release the door handle cable from the door carrier.
2 Release the door carrier retaining clip.
3 Position aside the interior door handle.
5. Release the cable from the handle.
6. NOTE: Make sure the interior door handle spring has been realigned before installation of the
door handle. Check for normal operation.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System
Information > Adjustments > Hinge Adjustment - Door, Rear, Fore, Aft and Tilt
Rear Door Hinge: Adjustments Hinge Adjustment - Door, Rear, Fore, Aft and Tilt
HINGE ADJUSTMENT - DOOR, REAR, FORE, AFT AND TILT
1. Position the front seat in the full forward position.
2. Remove the door striker. 3. Remove the lower B-pillar trim panel.
4. Remove the B-pillar weathershield.
5. Loosen the hinge-to-B-pillar nuts enough to allow movement of the rear door. 6. Adjust the rear
door until it is uniform to adjacent panels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System
Information > Adjustments > Hinge Adjustment - Door, Rear, Fore, Aft and Tilt > Page 8880
7. Tighten the hinge-to-B-pillar nuts.
8. Install the B-pillar weathershield. 9. Install the lower B-pillar trim panel.
10. Install the door striker.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System
Information > Adjustments > Hinge Adjustment - Door, Rear, Fore, Aft and Tilt > Page 8881
Rear Door Hinge: Adjustments Hinge Adjustment - Door, Rear, In, Out, Up and Down
HINGE ADJUSTMENT - DOOR, REAR, IN, OUT, UP AND DOWN
1. Remove the door striker.
2. Loosen the hinge-to-door bolts enough to allow door movement. 3. Adjust the door until it is
uniform to adjacent panels.
4. Tighten the hinge-to-door bolts.
5. Install the door striker.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair
Rear Door Latch: Service and Repair
REAR DOOR LATCH
Removal and Installation
NOTE: The rear door window glass must be completely raised.
1. Remove rear door trim panel. 2. Position the watershield aside.
3. Remove the childproof door lock cover.
4. Disconnect the exterior door handle actuating rod.
- Open the clip.
5. Remove the bolts and position the rear door latch aside.
- Discard the bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Page 8885
6. Disconnect the electrical connectors.
7. Release the interior door cable and remove the rear door latch.
1 Position the cable cover aside.
2 Release the conduit and the interior door cable.
8. To install, reverse the removal procedure.
- Transfer parts as necessary.
- If necessary, use multi-purpose grease to lubricate the latch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair
Rear Door Panel: Service and Repair
REAR DOOR TRIM PANEL
Removal and Installation
NOTE: Left rear door shown, right rear similar.
1. If equipped with power windows, remove the window control switch plate.
- Use service notch.
2. Remove the door handle bezel.
- Use service notch.
3. CAUTION: To avoid damage to the door trim panel, lift the door trim panel by pulling directly
upward on the armrest to disengage the
panel clips.
Remove the two bolts and three screws, and remove the door trim panel. Remove the finish cover to access the two center screws.
- If equipped, disconnect the electrical connector.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Rear Door Window Glass
Rear Door Window Glass: Service and Repair Rear Door Window Glass
REAR DOOR WINDOW GLASS
Removal and Installation
1. Remove the rear door trim panel.
2. Position back the rear door weathershield. 3. Connect the window control switch. 4. Lower the
window glass to access the two window glass to regulator bolts.
5. Remove the inside glass weatherstrip.
6. Remove the rear door glass channel bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Rear Door Window Glass > Page 8893
7. Remove the window glass to regulator bolts and rear door window glass. 8. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Rear Door Window Glass > Page 8894
Rear Door Window Glass: Service and Repair Stationary
REAR DOOR WINDOW GLASS - STATIONARY
Removal and Installation
1. Remove the rear door window glass.
2. Remove the rear door exterior glass moulding. 3. Remove the rear door glass top run.
4. Remove the rear door stationary glass screw.
5. Remove the stationary rear door glass. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Locations > Left Rear
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Locations > Left Rear > Page 8899
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Left > Page 8902
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Diagrams > Page 8903
Rear Door Window Motor: Service and Repair
REAR DOOR WINDOW REGULATOR MOTOR
Removal and Installation
1. Remove the rear door trim panel.
2. Position the rear door weathershield aside.
3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window
regulator assembly to hold the window regulator
assembly drum in place.
Remove the rear door window regulator motor. 1
Disconnect the electrical connector.
2 Remove the bolts.
4. To install, reverse the removal procedure.
- Cycle the door glass to make sure of gear engagement.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
REAR DOOR WINDOW REGULATOR
Removal and Installation
1. Remove the rear door trim panel.
2. Remove the rear door speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
3. Remove the rear door weathershield. 4. Connect the window control switch. 5. Lower the
window glass to access the two window glass-to-regulator bolts. 6. Disconnect the window control
switch.
7. Remove the window glass-to-regulator bolts and rear door window glass.
8. NOTE: Secure the rear window glass in the full up position.
Secure the rear window glass with tape to the front door frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Page 8907
9. Disconnect the rear door window regulator electrical connectors.
10. Position the interior door handle aside.
- Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of
the bracket.
11. Remove the rear door window regulator assembly.
- Remove the bolts.
12. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair
Hood Latch: Service and Repair
HOOD LATCH
Removal and Installation
All vehicles 1. Raise and support the hood.
2. Remove the pin-type retainers and the upper radiator sight shield.
Expedition
3. Remove the bolts and the hood latch.
4. Release the hood latch cable from the hood latch.
Navigator
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair > Page 8912
5. Remove the screw and secondary hood release cable.
6. Remove the bolts and the hood latch.
7. Remove the hood latch cables.
1 Release the primary hood latch cable.
2 Release the secondary hood latch cable.
All vehicles 8. To install, reverse the removal procedure.
- Verify the hood latch engages the striker in the latched position (secondary).
- Verify the hood latch engages the striker in the fully latched position (primary).
- Adjust the hood latch as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair
Liftgate Window Glass: Service and Repair
LIFTGATE WINDOW GLASS
Removal and Installation
1. Remove the rear window wiper motor.
2. Disconnect the rear window defrost electrical connectors.
3. CAUTION:
- The liftgate glass must be supported when removing and installing the liftgate assist cylinders.
- Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can occur
Disconnect the two liftgate glass assist cylinders. 1
Insert a screwdriver blade under the socket clip and lift.
2 Gently pull the socket off the ball stud.
4. Remove the liftgate glass hinge bolts and remove the glass.
- Apply High Strength Threadlocker to the liftgate glass hinge bolts during installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control
Module > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 8920
Power Trunk / Liftgate Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 8921
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 8922
Power Trunk / Liftgate Control Module: Service and Repair
POWER LIFTGATE MODULE
Removal and Installation
NOTE: Prior to removal of the power liftgate module, it is necessary to upload module configuration
information to a diagnostic tool. This information needs to be downloaded into the new power
liftgate module once installed.
1. Remove the rear quarter trim panel.
2. Remove the power liftgate module.
1 Disconnect the electrical connectors.
2 Remove the bolts.
3. NOTE: Once the new power liftgate module is installed, it is necessary to download the module
configuration information from the diagnostic
tool into the new power liftgate module.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 8927
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 8930
Power Trunk / Liftgate Lock Actuator: Diagrams Liftgate Lock Actuator
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 8934
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard
Sensor > Component Information > Service and Repair
Power Trunk / Liftgate Hazard Sensor: Service and Repair
PINCH STRIP SWITCH
Removal and Installation
NOTE: Left side shown, right side similar.
1. Remove brake light.
- Remove the screws.
2. Disconnect the pinch strip electrical connector.
3. Remove the pinch strip.
1 Remove the pin-type retainers.
2 Remove the grommet and route the harness out of the vehicle.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Adjustments
Trunk / Liftgate Hinge: Adjustments
HINGE ADJUSTMENT - LIFTGATE
1. Loosen the liftgate hinge to liftgate bolts.
2. Adjust the liftgate alignment.
3. NOTE: The bolt washers must make full contact with the liftgate bracket when tightened.
Tighten the liftgate hinge to liftgate bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair
Trunk / Liftgate Handle: Service and Repair
LIFTGATE RELEASE HANDLE
Removal and Installation
All Vehicles 1. Remove the liftgate trim panel. 2. Position the watershield aside.
Expedition
3. Remove the nuts and position the liftgate release handle aside.
4. Release the cable from the liftgate release handle and remove the handle.
Navigator
5. Remove the liftgate release handle nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair > Page 8944
6. NOTE: Release the clips on the inside of license plate housing.
Remove the license plate housing. 1
Disconnect the electrical connectors.
2 Remove the 6 nuts.
7. Release the liftgate release handle from the liftgate.
8. Disconnect the electrical connector and release the cable from the liftgate handle and remove
the handle.
All vehicles 9. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch
Trunk / Liftgate Latch: Service and Repair Liftgate Latch
LIFTGATE LATCH
Removal and Installation
All vehicles 1. Remove the liftgate trim panel. 2. Position the watershield aside.
Vehicles with manual liftgate
3. Disconnect the electrical connectors.
Vehicles with power liftgate
4. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it.
Disconnect the liftgate latch. 1
Disconnect the liftgate latch control cable.
2 Release the door lock actuator rod.
3 Release the actuating rod.
4 Disconnect the electrical connector.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 8949
5. Remove the screws and position the liftgate latch aside.
- Discard the screws.
Vehicles with manual liftgate
6. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it from the
latch.
Disconnect the liftgate latch control cable. Remove the latch.
Vehicles with power liftgate
7. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it from the
latch.
Disconnect the liftgate latch control cable. Remove the liftgate latch.
All vehicles 8. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 8950
Trunk / Liftgate Latch: Service and Repair Liftgate Latch - Window Glass
LIFTGATE LATCH - WINDOW GLASS
Removal and Installation
1. Remove the liftgate trim panel. 2. Open the liftgate window glass.
3. Remove the liftgate window glass latch.
1 Disconnect the electrical connector.
2 Remove the bolts.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 8951
Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control
LIFTGATE LATCH REMOTE CONTROL
Removal and Installation
1. Remove the liftgate trim panel. 2. Position the watershield aside.
3. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it from the
latch.
Disconnect the liftgate latch. 1
Release the actuating rod.
2 Disconnect the liftgate latch control cable.
4. Remove bolts and position the liftgate remote control aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 8952
5. Disconnect the electrical connectors and remove the liftgate latch remote control. 6. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Locations > Liftgate Cinching Motor
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Locations > Liftgate Cinching Motor > Page 8957
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Locations > Liftgate Cinching Motor > Page 8958
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Liftgate Cinching Motor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Liftgate Cinching Motor > Page 8961
Trunk / Liftgate Motor: Diagrams Liftgate Driver Motor Assembly
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Liftgate Cinching Motor > Page 8962
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Liftgate Cinching Motor > Page 8963
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Page 8964
Trunk / Liftgate Motor: Service and Repair
POWER LIFTGATE MOTOR
Removal and Installation
1. Disconnect the battery ground cable and wait at least one minute.
2. NOTE: RH side shown, LH side similar.
Position the front and rear door seals aside.
3. Remove the C-pillar trim panel. 4. Remove the D-pillar trim panel.
5. CAUTION: To prevent damage to the coat hanger retainer, use a 3/16-inch flat-blade
screwdriver for this step.
Remove the four coat hooks. Open the access cover.
- Insert a screwdriver into the slot and rotate.
6. If equipped with rear climate control, remove the center pin-type retainers.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Page 8965
7. Remove the rear pin-type retainers.
8. CAUTION: To avoid damaging the headliner, do not crease or bend it.
Partially lower the headliner to access the power liftgate motor.
9. Remove the upper liftgate trim.
10. Position the wiring harness aside.
11. Remove the power liftgate motor to liftgate bolts.
12. Disconnect the electrical connectors and remove the power liftgate motor bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams > Page 8966
13. Remove the power liftgate motor pivot bolt. 14. Slide the power liftgate motor assembly forward
and remove the power liftgate motor. 15. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid >
Component Information > Service and Repair
Trunk / Liftgate Solenoid: Service and Repair
LIFTGATE LATCH ACTUATOR
Heavy Duty Riveter
Special Tool(s)
Removal and Installation
1. Remove the liftgate trim panel. 2. Position the watershield aside.
3. Release the actuating rod.
4. Remove the liftgate actuator.
1 Disconnect the electrical connector.
2 Remove the rivet.
3 Remove the liftgate actuator.
5. To install, reverse the removal procedure.
- Use the Heavy Duty Riveter to install the new rivet.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker >
Component Information > Service and Repair
Trunk / Liftgate Striker: Service and Repair
REAR WINDOW STRIKER AND WIPER PIVOT SHAFT ASSEMBLY
Removal
1. Remove the rear wiper pivot arm.
2. Remove the dust boot cover.
3. Remove the nut and the rear window glass handle.
4. Remove the nuts and the rear window striker and wiper pivot shaft assembly.
Installation
1. Remove the liftgate trim panel.
2. NOTE: An audible click should be heard as the striker engages the latch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker >
Component Information > Service and Repair > Page 8973
Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft
pin should be aligned with the hole in the motor disc.
3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is
provided with the motor assembly.
1 Make sure the alignment tool fits over the motor disc and striker assembly.
2 Make sure the alignment tool clips are securely engaged.
4. Carefully close the liftgate glass.
5. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly
nuts.
6. Remove the rear window wiper motor alignment tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker >
Component Information > Service and Repair > Page 8974
7. Close the liftgate.
8. Install the rear window wiper pivot shaft nut and handle.
9. Install the dust boot cover.
10. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn
the rear window wiper switch to OFF.
11. Install the rear wiper pivot arm onto the rear window wiper motor shaft.
1 Position the wiper pivot arm onto the rear window wiper motor shaft.
2 Tighten the nut.
3 Install the cover.
12. Open the liftgate. 13. Install the liftgate trim panel. 14. Test the liftgate and liftgate glass for
normal operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 8979
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 8980
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 8983
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 8984
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Remove the windshield wipers. 2. Remove the cowl grille seal.
3. Remove the pin-type retainer and left side cowl trim panel.
- Disconnect the windshield washer tube.
4. Remove the right side cowl trim panel.
1 Disconnect the windshield washer tube.
2 Remove the pin-type retainer.
5. If necessary, adjust the windshield wiper arms. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair
Front Fender: Service and Repair
FENDER - EXPEDITION
Removal and Installation
NOTE: Left side shown, right side similar.
1. Remove the front fender splash shield.
2. Remove the front fender to front bumper cover bolts.
3. Remove the front fender to radiator support bolt.
4. Remove the front fender lower bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page
8993
5. Remove the foam insulator.
- Remove the pin-type retainer.
6. Remove the front fender inner bolts.
7. Loosen the headlamp retaining bolt.
8. Remove the headlamp.
- Remove the bolts and disconnect the electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page
8994
9. Remove the front fender front bolts.
10. Remove the cowl panel grille.
11. Remove the front fender.
- Remove the bolts.
12. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations
> Page 8999
Body / Frame Mount Bushing: Description and Operation
FRAME AND BODY MOUNTING
Frame Components
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations
> Page 9000
Radiator Support Mount
No.1 Body Mount
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations
> Page 9001
No.2 Body Mount
No.3 Body Mount
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations
> Page 9002
No.4 Body Mount
Spare Tire Winch
The frame (5005) is made up of two steel boxed side rails and crossmembers, which are welded to
the two side rails. The transmission crossmember is bolted to the side rails. The side welded rails
and crossmembers are not replaced separately.
The service kits available for the frame are:
- RH front horn replacement kit (5D058).
- LH front horn replacement kit (5D059).
- Front bumper bracket replacement kit (17N775).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations
> Page 9003
- 1B crossmember replacement kit (5C075).
- Transmission crossmember replacement kit (5059).
Refer to the instructions included in the kits for installation instructions.
Frame Mounted Heat Shields
All frame mounted heat shields are torqued to 15 Nm (11 lb-ft).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1
Body / Frame Mount Bushing: Service and Repair Body Support - Number 1
BODY SUPPORT - NUMBER 1
Removal and Installation
WARNING: If equipped with air suspension, the electrical power to the air suspension system must
be shut down prior to hoisting, jacking or towing an air suspension equipped vehicle. This can be
accomplished by turning off the air suspension switch located at the left rear interior of the vehicle.
Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in
shifting of the vehicle during these operations.
NOTE: Left side shown, right side similar.
1. Remove the body mount bolt. 2. Loosen the remaining body mount bolts.
3. Raise the vehicle body enough to remove the body mount bolts and body mount.
4. NOTE:
- No lubricants of any kind are to be used during body mount installation.
- Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has
been removed or loosened.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9006
Body / Frame Mount Bushing: Service and Repair Body Support - Number 2 and Number 3
BODY SUPPORT - NUMBER 2 AND NUMBER 3
Removal and Installation
WARNING: If equipped with air suspension, the electrical power to the air suspension system must
be shut down prior to hoisting, jacking or towing an air suspension equipped vehicle. This can be
accomplished by turning off the air suspension switch located at the left rear interior of the vehicle.
Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in
shifting of the vehicle during these operations.
NOTE: Body mount number two, left side shown, all others similar.
Upper and lower body mount
1. Remove the body mount bolt and lower body mount.
Upper body mount
2. Loosen the remaining body mount bolts.
3. Raise the vehicle body enough to remove the upper body mount.
Upper and lower body mount
4. NOTE:
- No lubricants of any kind are to be used during body mount installation.
- Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has
been removed or loosened.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9007
Body / Frame Mount Bushing: Service and Repair Body Support - Number 4
BODY SUPPORT - NUMBER 4
Removal and Installation
WARNING: If equipped with air suspension, the electrical power to the air suspension system must
be shut down prior to hoisting, jacking or towing an air suspension equipped vehicle. This can be
accomplished by turning off the air suspension switch located at the left rear interior of the vehicle.
Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in
shifting of the vehicle during these operations.
NOTE: Left side shown, right side similar.
1. Remove the liftgate scuff plate.
2. Remove the body mount bolt cover.
3. Remove the body mount nut. 4. Loosen the remaining body mount bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9008
5. Raise the vehicle body enough to remove the body mount bolts.
6. NOTE:
- No lubricants of any kind are to be used during body mount installation.
- Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has
been removed or loosened.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9009
Body / Frame Mount Bushing: Service and Repair Body Support - Radiator Support
BODY SUPPORT - RADIATOR SUPPORT
Removal and Installation
WARNING: If equipped with air suspension, the electrical power to the air suspension system must
be shut down prior to hoisting, jacking or towing an air suspension equipped vehicle. This can be
accomplished by turning off the air suspension switch located at the left rear interior of the vehicle.
Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in
shifting of the vehicle during these operations.
NOTE: Left side shown, right side similar.
Upper and lower body mount
1. Remove the lower radiator body mount.
1 Remove the lower radiator body mount bolt.
2 Remove the lower radiator body mount.
Upper body mount
2. Loosen the remaining body mount bolts.
3. Raise the vehicle body enough to remove the upper body mount.
Upper and lower body mount
4. NOTE:
- No lubricants of any kind are to be used during body mount installation.
- Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has
been removed or loosened.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair > Spot Welds - Rear Cross Member & Side Members
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 9015
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 9016
Rear Cross-Member: Service and Repair Crossmember - Transmission
CROSSMEMBER - TRANSMISSION
Removal and Installation
1. Raise and support the vehicle.
2. Remove the transmission mount nuts. 3. Support the transmission.
4. Remove the transmission crossmember bolts and transmission crossmember. 5. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair
Trailer Hitch: Service and Repair
TRAILER HITCH
Removal and Installation
WARNING: Do not permanently remove the trailer hitch. Always reinstall the hitch before delivery
of the vehicle to the customer. Failure to follow this warning could increase the risk of injury in a
rear end collision.
1. Raise and support the vehicle. 2. Remove the trailer hitch rear bumper cover trim panel.
3. Remove the trailer lighting plug cover and disconnect the electrical connector.
4. Remove the trailer lighting plug.
1 Position the plug away from the trailer hitch.
2 Disconnect the electrical connector.
3 Remove the trailer lighting plug.
5. Remove the trailer hitch.
- Remove the eight bolts.
6. NOTE: Do not reuse body support mounting fasteners. New fasteners must be installed for each
fastener that has been removed or loosened.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
9023
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
9024
Trailer Towing Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
9025
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and
Repair
Arm Rest: Service and Repair
SEAT ARMREST - SECOND ROW
Removal and Installation
1. To access the armrest locking metal clip, pull the armrest material back on the top side of the
armrest for access to the release clip.
2. CAUTION: To remove armrests, do not pull them off with force. The locking metal clip will be
damaged and a new armrest will need to
be installed.
NOTE: Armrest removed to show detail of release button mechanism.
Use a tool such as a flat-bladed screwdriver to push the release button at the hinge point. The clip
will release and the armrest will slide off the pin.
3. CAUTION: To install armrests, do not push them on with force. The locking metal clip will be
damaged and a new armrest will need to
be installed.
To install, reverse the removal procedure. To install the armrest, push the release button and slide the armrest on the pin.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description
and Operation > Console - Floor
Console: Description and Operation Console - Floor
CONSOLE - FLOOR, FRONT
The front floor console may consist of the following components:
- A/C integral control assembly
- A/C register (upper)
- auxiliary A/C controls
- auxiliary power point
- center console finish panel
- console finish panel mat
- compact disc player mounting bracket
- compact disc player compartment trim panel
- digital audio compact disc player
- shift lever (Navigator)
- window control switch panel (Navigator)
- navigation system display module
- navigation system module
- video cassette player
CONSOLE - FLOOR, REAR
The rear console consists of the following components:
- armrest
- cup holders
- storage bin
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description
and Operation > Console - Floor > Page 9034
Console: Description and Operation Console - Overhead
CONSOLE - OVERHEAD
There are two versions of the overhead console, with and without the roof opening panel.
The overhead console with the roof opening panel may contain the following:
- climate controls (optional)
- map lamps/switches
- roof opening panel switch
- rear quarter window switches (optional)
The overhead console without the roof opening panel may contain the following:
- climate controls (optional)
- glasses storage bin
- map lamps/switches
- rear quarter window switches (optional)
- storage bin
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Front
Console: Service and Repair Floor Console - Front
FLOOR CONSOLE - FRONT
REMOVAL
1. Position the front seat forward.
2. Remove the two front floor console rear bolts. 3. Position the front seats rearward. 4. Disconnect
the battery.
5. Remove the console finish panel.
1 Remove the mat.
2 Remove the screw.
- Disconnect the electrical connectors.
6. Disconnect the front floor console electrical connectors.
1 Loosen the electrical connector bolt.
2 Disconnect the electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Front > Page 9037
7. Remove the floor console.
1 Remove the screws.
2 Remove the bolts.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console - Front > Page 9038
Console: Service and Repair Floor Console - Rear
FLOOR CONSOLE - REAR
REMOVAL
1. Remove the rear floor console.
1 Open the front bin.
2 Remove the cup holder.
3 Remove the bolts.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9044
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9045
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9046
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9047
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9048
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9049
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9050
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9051
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9052
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9053
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9054
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9055
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 9056
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information >
Service and Repair
Glove Compartment: Service and Repair
GLOVE COMPARTMENT
REMOVAL
1. CAUTION: Forcing the glove compartment past the stops will damage the dampener.
Open the glove compartment.
2. Disconnect the dampener.
3. Release the stops.
4. Remove the screws and the glove compartment.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair
Headliner: Service and Repair
HEADLINER
Removal and Installation
All vehicles 1. Disconnect the battery ground cable and wait at least one minute.
2. Position aside the front and rear door seals.
3. If equipped, remove the roof opening panel trim.
4. Remove the A-pillar trim panels.
- Remove the bolt covers and bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 9063
5. If equipped, remove the electronic compass sensor.
6. If equipped, disconnect the auto dimming mirror electrical connector.
7. Remove the two sun visors and visor clips.
1 Remove the eight screws.
2 Remove the two sun visors and visor clips. If equipped, disconnect the electrical connectors.
8. If equipped, remove the overhead console. 9. If equipped, remove the DVD player.
10. Remove the upper B-pillar trim panel. 11. Remove the C-pillar trim panel. 12. Remove the
D-pillar trim panel.
13. CAUTION: To prevent damage to the coat hanger retainer, use a 3/16-inch flat-blade
screwdriver for this step.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 9064
Remove the four coat hooks. Open the access cover.
- Insert a screwdriver into the slot and rotate.
14. Disconnect the two electrical connectors at the right side C-pillar and one electrical connector
at the left side C-pillar.
Vehicles equipped with rear climate control
15. Remove the center pin-type retainers.
16. Remove the rear pin-type retainers.
17. Tilt the headliner to release the vent duct.
All vehicles 18. Remove the headliner. 19. To install, reverse the removal procedure.
- Transfer parts as necessary.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel
Trim Panel: Service and Repair B-Pillar Trim Panel
B-PILLAR TRIM PANEL
Removal and Installation
NOTE: Left side shown, right side similar.
Upper and lower
1. NOTE:
- Position the safety belt guide to the lowest position.
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or cover does not remain closed, install a new shoulder safety belt guide cover.
Remove the safety belt guide. Lift up on the cover and remove the nut.
2. Remove the upper B-pillar trim panel.
- Remove the bolt cover and bolt.
- Remove the upper B-pillar trim panel by pulling outward to release the clips.
Lower 3. Remove the front and rear door scuff plates.
4. Position the lower B-pillar trim panel aside.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9069
5. Remove the front safety belt anchor. 6. Feed the safety belt through the lower B-pillar trim panel
and remove.
Upper and lower 7. To install, reverse the removal procedure.
- When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper
B-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9070
Trim Panel: Service and Repair C-Pillar Trim Panel
C-PILLAR TRIM PANEL
Removal and Installation
NOTE: Right side shown, left side similar.
1. NOTE:
- Position the safety belt guide to the lowest position.
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or cover does not remain closed, install a new shoulder safety belt guide cover.
Remove the safety belt guide. Lift up on the cover and remove the nut.
2. Remove the C-pillar trim panel.
- Remove the bolt cover and bolt and pull outward to release the retainers.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9071
Trim Panel: Service and Repair D-Pillar Trim Panel
D-PILLAR TRIM PANEL
Removal and Installation
NOTE: Right side with power vent windows and power liftgate shown, all others similar.
1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide
cover is damaged or cover does not remain
closed, install a new shoulder safety belt guide cover.
Remove the safety belt guide. Lift up on the cover and remove the nut.
2. Remove rear upper headliner trim panel.
3. Remove the D-pillar trim panel.
1 Disengage the upper clip by pulling downward.
2 Unseat the D-pillar trim panel and rotate forward to remove.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9072
Trim Panel: Service and Repair Liftgate Trim Panel
LIFTGATE TRIM PANEL
Removal and Installation
1. Open the liftgate glass and remove the scrivets.
2. Open the liftgate and remove the upper liftgate trim panel.
- Pull lower corners toward the center on both sides and pull down along the top.
3. Remove the assist handle.
1 Remove the screws.
2 Remove the assist handle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9073
4. Remove the lower liftgate trim panel.
1 Hold the trim panel at the center area and slightly pull on the center clips to allow a tool to access
the clips.
2 Release the 12 clips 2 to 3 at a time, starting from the right side working to the left side.
3 Once all the clips are released, slide the liftgate trim panel forward and down, away from the
sheet metal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9074
Trim Panel: Service and Repair Rear Quarter Trim Panel
REAR QUARTER TRIM PANEL
Removal and Installation
1. Remove the C-pillar trim panel. 2. Remove the D-pillar trim panel.
3. Remove the liftgate scuff plate by pulling upward.
4. Remove the rear floor loadspace trim panel.
5. Remove the floor jack assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9075
6. Remove the pin-type retainers and pull back the carpeting.
7. Remove the two bolts and the loadspace trim panel by pulling upward.
8. Remove the third row seat safety belt anchor bolt.
9. Remove the rear quarter trim panel pin-type retainer.
10. Remove the second row safety belt anchor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > B-Pillar Trim Panel > Page 9076
11. Remove the rear door scuff plate by pulling upward.
12. NOTE: The seat back must not be folded completely down, as the quarter trim panel will not
have enough clearance to be removed.
Fold the seat back of the third row seat downward so that the top edge of the seat back is
positioned within approximately 203 mm (8 in) of the full down position.
13. Remove the rear quarter trim panel.
- Disengage the rear clip on the base of the trim panel first, by pulling the bottom rear edge toward
the center of the vehicle.
- Disengage the remaining clips.
- If equipped, disconnect the power point and power third row seat switch electrical connector at
the rear.
14. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair
Door Lock Cylinder: Service and Repair
DOOR LOCK CYLINDER
Removal and Installation
NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and
building a new lock cylinder using the appropriate lock repair package. The lock repair package
includes a detailed instruction sheet to build the new lock cylinder to the current code of the
vehicle.
1. Remove the exterior front door handle.
2. Remove the front door lock cylinder.
1 Disconnect the lock cylinder rod.
2 Remove the retainer.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9087
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 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9088
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 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9089
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9090
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Service and Repair > Remote Keyless Entry Keypad Code Programming
Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad Code Programming
REMOTE KEYLESS ENTRY KEYPAD CODE PROGRAMMING
1. Enter the permanent factory remote keyless entry (RKE) keypad code. 2. Press the 1/2 button
within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2
seconds after activation erases
the stored customer code. The door locks will lock, then unlock, confirming the code is erased. The
existing code does not need to be erased to program a new code.
3. Within 5 seconds, enter the new 5-digit RKE keypad code. The doors lock and unlock to confirm
the new code is programmed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 9093
Keyless Entry Key-Pad: Service and Repair Autolock and Horn Chirp Programming
AUTOLOCK AND HORN CHIRP PROGRAMMING
1. Close all the doors. 2. Confirm that the ignition switch is in the OFF position. 3. Turn the ignition
switch from OFF to RUN.
4. NOTE: Steps 4 through 8 must be carried out within 30 seconds.
Press the power door lock UNLOCK button 3 times.
5. Turn the ignition switch from RUN to OFF. 6. Press the power door lock UNLOCK button 3
times. 7. Turn the ignition switch from OFF to RUN. 8. Verify that the horn chirps. This indicates the
system is in the enable/disable mode is ready to accept program changes. 9. Press the power door
lock UNLOCK button one time to toggle the autolock/relock feature OFF.
10. Press the power door lock LOCK button once to enter the command. 11. Verify that the horn
chirps one time. There should only be one chirp indicating that autolock/relock feature has been
disabled. If one chirp is
heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled.
Return to Step 9.
12. Turn the ignition switch to the OFF position to exit the enable/disable mode. 13. Exit the vehicle
and verify that the horn chirps once to indicate that a feature has been changed and that
autolock/relock has been disabled.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 9094
Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad
REMOTE KEYLESS ENTRY KEYPAD
Removal and Installation
1. Remove the exterior mirror.
2. Disconnect the electrical connector. 3. Remove the front door window glass.
4. CAUTION: Damage to the base moulding may occur during the removal procedure.
Remove the front door window base molding.
5. Remove the remote keyless entry (RKE) keypad. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Application and ID
Keyless Entry Module: Application and ID
RKE TRANSMITTER/RKE KEYPAD
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair
Keyless Entry Transmitter: Service and Repair
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING
NOTE:
- All remote keyless entry (RKE) transmitters must be programmed at the same time.
- Programming (or reprogramming) of the RKE transmitters can be accomplished using a
diagnostic tool or by carrying out the following steps:
1. The vehicle must be electronically unlocked before entering program mode using the door lock
control switch while the driver door is open. 2. Turn the ignition switch from the OFF to the RUN
position 8 times within 10 seconds, with the eighth turn ending in RUN. If the module has
successfully entered program mode, it will lock and then unlock all doors.
3. Within 20 seconds, press any button on a RKE transmitter, and the doors will lock and then
unlock to confirm that each RKE transmitter has been
programmed. Repeat this step for each RKE transmitter.
4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the
button again. If the door locks still fail to respond,
refer to Inspection and Verification. (Make sure that no more than the maximum number of RKE
transmitters are attempted to be programmed.) See: Power Locks/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Inspection and Verification
5. Exiting the programming mode is accomplished if one of the following occurs:
- The key transitions to the OFF position.
- 20 seconds have passed since entering programming mode or since the last RKE transmitter was
programmed.
- The maximum number (6) of RKE transmitters have been programmed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear > Page 9106
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear > Page 9107
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear > Page 9108
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9111
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9112
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9113
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator
Power Door Lock Actuator: Service and Repair Front Door Lock Actuator
FRONT DOOR LOCK ACTUATOR
Removal and Installation
1. Remove the front door latch.
2. Release the locking tab and remove the front door lock actuator. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator > Page 9116
Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator
REAR DOOR LOCK ACTUATOR
Removal and Installation
1. Remove the rear door latch.
2. Release the locking tab and remove the rear door lock actuator. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Application and ID
Power Door Lock Control Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Driver Side
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Driver Side > Page 9124
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Driver Side
Power Door Lock Switch: Diagrams Driver Side
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Driver Side > Page 9127
Power Door Lock Switch: Diagrams Passenger Side
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 9128
Power Door Lock Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 9129
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9135
Memory Positioning Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9136
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9140
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9141
Seat Memory Switch: Testing and Inspection
SWITCH - MEMORY SET
Memory Set Switch
Remove the memory set switch.
Measure the resistance between the indicated terminals while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to
the calling pinpoint test.
NOTE: Refer to multimeter user's manual for testing diodes.
To check the memory set switch LED, connect the positive meter lead to terminal 7 and the
negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, install a new switch; otherwise, return to the
calling pinpoint test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
Power Mirror Motor: Service and Repair
EXTERIOR MIRROR MOTOR
Removal and Installation
1. Remove the mirror glass.
2. Remove the three exterior mirror motor screws and exterior mirror motor.
- Disconnect the electrical connectors.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9148
Power Mirror Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9149
Power Mirror Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9150
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9151
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
Removal and Installation
All vehicles 1. Remove the driver front door trim panel.
Navigator
2. Depress the locking tabs and remove the exterior mirror control switch.
Expedition
3. Remove the exterior mirror control switch.
1 Depress the locking tabs.
2 Remove the exterior mirror control switch.
All vehicles 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Customer Interest: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim
Paint: Customer Interest Body - Paint Bubbles Around Liftgate Trim
TSB 07-2-9
02/05/07
PAINT BUBBLES AROUND LIFTGATE TRIM
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting
around the trim area on the liftgate. This can occur when the trim part moves on the paint surface
because of climate temp changes and/or owner operation. Overtime these trim parts can rub
through the paint surface and cause corrosion to start developing between the aluminum gate and
paint.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Paint resurfacing will be necessary to correct the paint bubbling concern.
2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket
for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will
act as a friction barrier between the paint surface and the trim components.
3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates.
This can be done by wiping the surface with a 50% solution of isopropyl alcohol and water.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Customer Interest: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim > Page 9161
4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the
tape after its been applied for a clean fit.
5. After applying the Mylar tape, follow installation procedure for each part as listed in the
appropriate Workshop Manual, Section 501.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
070209A 2003-2006 Expedition: 1.3 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim
(Do Not Use With P42D)
070209B 2003-2006 Navigator: 1.1 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim
(Do Not Use With P42D)
070209C 2003-2006 Expedition: 2.4 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
070209C 2003-2006 Navigator: 2.2 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78404C42 D7
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim
Paint: All Technical Service Bulletins Body - Paint Bubbles Around Liftgate Trim
TSB 07-2-9
02/05/07
PAINT BUBBLES AROUND LIFTGATE TRIM
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting
around the trim area on the liftgate. This can occur when the trim part moves on the paint surface
because of climate temp changes and/or owner operation. Overtime these trim parts can rub
through the paint surface and cause corrosion to start developing between the aluminum gate and
paint.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Paint resurfacing will be necessary to correct the paint bubbling concern.
2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket
for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will
act as a friction barrier between the paint surface and the trim components.
3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates.
This can be done by wiping the surface with a 50% solution of isopropyl alcohol and water.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim >
Page 9167
4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the
tape after its been applied for a clean fit.
5. After applying the Mylar tape, follow installation procedure for each part as listed in the
appropriate Workshop Manual, Section 501.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
070209A 2003-2006 Expedition: 1.3 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim
(Do Not Use With P42D)
070209B 2003-2006 Navigator: 1.1 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim
(Do Not Use With P42D)
070209C 2003-2006 Expedition: 2.4 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
070209C 2003-2006 Navigator: 2.2 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78404C42 D7
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 04-9-6 > Apr > 04 > Paint - Repair Due To Iron Particles/Acid Rain
Paint: All Technical Service Bulletins Paint - Repair Due To Iron Particles/Acid Rain
Article No. 04-9-6
BODY - PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN
NEUTRALIZATION
FORD: 2004-2005 CROWN VICTORIA, ESCORT ZX2, FOCUS, MUSTANG, TAURUS,
THUNDERBIRD
2005 FIVE HUNDRED, FORD GT 2005 FIVE HUNDRED, FORD GT 2004-2005 ECONOLINE,
ESCAPE, EXCURSION, EXPEDITION,EXPLORER SPORT TRAC, EXPLORER, F SUPER DUTY,
FREESTAR, RANGER, F SERIES, F-650, F-750
LINCOLN: 2004-2005 LS, TOWN CAR, AVIATOR, NAVIGATOR
MERCURY: 2004-2005 GRAND MARQUIS, SABLE
2005 MONTEGO 2004-2005 MONTEREY, MOUNTAINEER 2005 MARINER
This article supersedes TSB 99-12-10 to update the vehicle lines, model years and service
procedure.
ISSUE
Ford Motor Company has released a private labeled material to be used for iron particle/acid rain
service repairs.
ACTION
To remove these particles/contaminates, use ONLY the following Motorcraft products and
procedure. No polishing, compounding, color sanding, or repainting should be done before this
procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and
must be properly mixed and used in their specific order. Refer to the following Service Procedure
for details.
SERVICE PROCEDURE
NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY
CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES.
NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE
DESIGNED FOR VEHICLES, WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120
DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE
PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS
COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING
PROCEDURES AFTER VEHICLE INSPECTION.
IDENTIFICATION
Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc.
Moisture and heat combine with particles to create a chemical reaction. This reaction creates an
acid, causing the iron to corrode and etch into the paint surface. Additionally, industrial fallout and
acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected
to moisture and temperature, chemical compounds are created that etch the paint surface. To
assist in identifying surface contamination, use a (Tandy-Radio Shack #63-851) 30x lighted
magnifier.
CONCERN DESCRIPTION
Ferrous Metal
- Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is
rough to the touch.
- Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot.
The surface is rough to the touch.
Industrial Fallout
- Water spots containing ferrous metal are present and the surface is rough to the touch.
Acid Rain/Etching
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Paint: > 04-9-6 > Apr > 04 > Paint - Repair Due To Iron Particles/Acid Rain >
Page 9172
- Surface will exhibit irregular discolored spotting.
- Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the
paint.
- Extreme cases of etching may be felt.
DECONTAMINATION PROCEDURE
Use Motorcraft Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and
neutralize the paint surface. Perform the procedure only on vehicle when the paint surface
temperature is cool. Follow the step-by-step procedure listed below to perform this service
operation.
1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Motorcraft Acid
Neutralizer by mixing eight (8) parts of water to one (1) part Acid Neutralizer in a bucket. 3. Wear
gloves and use a clean wash mitt to apply mixture of Motorcraft Acid Neutralizer to the entire
vehicle starting at the top of the vehicle
working toward the side. Work fast and keep the vehicle wet with solution, lightly agitating and
moving quickly around the vehicle repeatedly for five to seven (5-7) minutes. For vehicles with
severe conditions, work the product for up to eight (8) minutes.
NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS.
4. Rinse the vehicle thoroughly with cold water to remove Motorcraft Acid Neutralizer. 5. Dry only
the horizontal surfaces of the vehicle at this time. Do not dry glass.
NOTE MOTORCRAFT ALKALINE NEUTRALIZER IS READY TO USE. DO NOT MIX WITH
WATER. DO NOT SPRAY MOTORCRAFT ALKALINE NEUTRALIZER ON THE PAINTED
SURFACE.
6. Pour the Alkaline Neutralizer into a dispenser (squirt bottle). Squirt the neutralizer directly onto a
clean wash mitt. Apply the product to the
vehicle, keeping the areas wet and lightly agitated for five to seven (5-7) minutes. For vehicles with
severe conditions, work the product for up to eight (8) minutes.
7. Rinse the vehicle thoroughly with cold water. 8. Prepare Motorcraft Detail Wash by mixing 29.5
mL (1 ounce) of Detail Wash to 3.7 L (1 gallon) of water. 9. Shampoo the vehicle with Motorcraft
Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle
completely.
SURFACE CORRECTION FOLLOWING DECONTAMINATION/NEUTRALIZATION
1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots.
NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES
DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN
EXTREME CASES, REFINISHING.
2. DO NOT intermix buffing products. Use only one manufacturer's products. 3. Always follow the
manufacturer's product usage sequence. Use the appropriate recommended pad at recommended
buffing speeds as specified by
the product manufacturer.
NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR
SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL
BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY
RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL.
4. Use a dual action sander with a Velcro backing plate and foam pad to fine polish and remove
any swirls created by a rotary buffer or pad. 5. Use an alcohol and water mixture (1 to 1 ratio) to
clean the buffed areas and to verify removal of scratches and swirls before application of the
final polish.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of
New Vehicle Limited Warranty Coverage
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Other Service Bulletins for Paint: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135
Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Other Service Bulletins for Paint: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and P2135
Set > Page 9178
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Other Service Bulletins for Paint: > Page 9179
Paint: By Symptom
Technical Service Bulletin # 07-2-9 Date: 070205
Body - Paint Bubbles Around Liftgate Trim
TSB 07-2-9
02/05/07
PAINT BUBBLES AROUND LIFTGATE TRIM
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting
around the trim area on the liftgate. This can occur when the trim part moves on the paint surface
because of climate temp changes and/or owner operation. Overtime these trim parts can rub
through the paint surface and cause corrosion to start developing between the aluminum gate and
paint.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Paint resurfacing will be necessary to correct the paint bubbling concern.
2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket
for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will
act as a friction barrier between the paint surface and the trim components.
3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates.
This can be done by wiping the surface with a 50%
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Other Service Bulletins for Paint: > Page 9180
solution of isopropyl alcohol and water.
4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the
tape after its been applied for a clean fit.
5. After applying the Mylar tape, follow installation procedure for each part as listed in the
appropriate Workshop Manual, Section 501.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
070209A 2003-2006 Expedition: 1.3 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim
(Do Not Use With P42D)
070209B 2003-2006 Navigator: 1.1 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim
(Do Not Use With P42D)
070209C 2003-2006 Expedition: 2.4 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
070209C 2003-2006 Navigator: 2.2 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78404C42 D7
Disclaimer
Technical Service Bulletin # 07-2-9 Date: 070205
Body - Paint Bubbles Around Liftgate Trim
TSB 07-2-9
02/05/07
PAINT BUBBLES AROUND LIFTGATE TRIM
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Other Service Bulletins for Paint: > Page 9181
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting
around the trim area on the liftgate. This can occur when the trim part moves on the paint surface
because of climate temp changes and/or owner operation. Overtime these trim parts can rub
through the paint surface and cause corrosion to start developing between the aluminum gate and
paint.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Paint resurfacing will be necessary to correct the paint bubbling concern.
2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket
for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will
act as a friction barrier between the paint surface and the trim components.
3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates.
This can be done by wiping the surface with a 50% solution of isopropyl alcohol and water.
4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the
tape after its been applied for a clean fit.
5. After applying the Mylar tape, follow installation procedure for each part as listed in the
appropriate Workshop Manual, Section 501.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > All Other Service Bulletins for Paint: > Page 9182
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
070209A 2003-2006 Expedition: 1.3 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim
(Do Not Use With P42D)
070209B 2003-2006 Navigator: 1.1 Hrs.
Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim
(Do Not Use With P42D)
070209C 2003-2006 Expedition: 2.4 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
070209C 2003-2006 Navigator: 2.2 Hrs.
Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For
P101 Basic Paint) (Do Not Use With P42)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78404C42 D7
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes
Paint: Application and ID Paint Codes
PAINT CODES
Vehicle Certification Label
Exterior Paint Code
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9185
Exterior Paint Code
Paint codes may be listed as a two-part code. The first set of characters listed indicate the vehicle
primary body color. The second set of characters listed (if applicable) indicate a two-tone or accent
body color. All colors are base coat/clear coat. CX - Dark Shadow Gray - Expedition
- DV - Light Tundra/Titanium Green - Navigator
- G2 - Redfire - Expedition/Navigator
- G3 - Pueblo Gold - Expedition/Navigator
- G4 - Cashmir (tri-coat) - Expedition/Navigator
- JP - Silver Birch Metallic - Expedition/Navigator
- LD - Medium Wedgewood Blue - Expedition
- ST - Estate Green - Expedition
- T3 - Satellite Silver - Navigator
- T7 - Charcoal Beige - Expedition/Navigator
- UA - Ebony - Expedition/Navigator
- YZ - Oxford White - Expedition/Navigator
Interior Trim
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9186
Interior Trim
Interior trim codes are listed as a two-part code. The first character identifies the trim type. The
second character identifies the interior trim color.
Trim Type 1 - Milled Pebble/Toscana leather captains chairs - Expedition
- 1 - Milled Pebble/Imola leather captains chairs - Expedition
- 2 - Milled Pebble/Imola low-back bucket seats - Expedition
- F - Port cloth captain's chairs - Expedition
- K - Milled Pebble/Imola leather low-back bucket seats - Navigator
- M - Cloth - 60/40 front (split bench) - Expedition
Interior Trim Color C - Camel Tan - Navigator
- D - Dove Gray - Navigator
- E - Medium Flint - Expedition
- H - Medium Parchment - Expedition
Tape/Paint Stripe
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9187
Tape/Paint Stripe
Tape and paint stripe codes do not apply.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9188
Paint: Application and ID Paint Code Sticker Location
PAINT CODE STICKER LOCATION
Vehicle Certification (VC) Label Locator
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9189
Paint: Application and ID Paint Code Information
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9190
Paint: Application and ID DSO Fleet Color Codes
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9191
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9192
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Application and ID
Keyless Entry Module: Application and ID
RKE TRANSMITTER/RKE KEYPAD
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9200
Memory Positioning Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9201
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Application and ID
Power Door Lock Control Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Application and ID
Power Seat Control Module: Application and ID
THIRD ROW POWER-FOLD SEAT
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Diagrams > Third Row Folding Seat Relay, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Diagrams > Third Row Folding Seat Relay, Left > Page 9213
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Testing and Inspection > Third Row Folding Seat Relay, Left
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 9216
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 9217
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 9218
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 9222
Power Trunk / Liftgate Control Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 9223
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control
Module > Component Information > Locations > Page 9224
Power Trunk / Liftgate Control Module: Service and Repair
POWER LIFTGATE MODULE
Removal and Installation
NOTE: Prior to removal of the power liftgate module, it is necessary to upload module configuration
information to a diagnostic tool. This information needs to be downloaded into the new power
liftgate module once installed.
1. Remove the rear quarter trim panel.
2. Remove the power liftgate module.
1 Disconnect the electrical connectors.
2 Remove the bolts.
3. NOTE: Once the new power liftgate module is installed, it is necessary to download the module
configuration information from the diagnostic
tool into the new power liftgate module.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 07-16-8 > Aug
> 07 > A/C - Front Seat Heaters Inoperative
Seat Heater Control Module: Customer Interest A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 07-16-8 > Aug
> 07 > A/C - Front Seat Heaters Inoperative > Page 9233
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9238
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9239
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9240
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9241
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9242
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9243
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9244
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9245
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9246
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul >
06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9247
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative
Seat Heater Control Module: All Technical Service Bulletins A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
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Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
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07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative > Page 9254
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
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06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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View 151-27 (Passenger Seat)
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Seat Heater Control Module: Diagrams
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Component Information > Technical Service Bulletins > Page 9273
Seat Heater Control Module: Service and Repair
CLIMATE CONTROLLED SEAT MODULE
Removal and Installation
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Position the front passenger seat all the way back and up. 2. Depower the SRS.
3. Pull out and remove the lower front seat track shield.
4. NOTE: The inset shows the dual climate control seat module (CCSM) retaining bracket.
Remove the dual CCSM. 1
Pull the back of the dual CCSM away from the seat and slide it off the mounting bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 9274
2 Disconnect the electrical connectors.
3 Remove the dual CCSM.
5. To install, reverse the removal procedure. 6. Repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9283
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9284
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9285
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9286
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9287
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9288
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9289
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9290
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9291
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9292
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9293
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9299
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9300
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9301
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9302
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9303
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9304
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9305
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9306
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9307
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9308
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C
- Climate Controlled Seats DTC B272C or B272D > Page 9309
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 9313
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 9317
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 9318
Trailer Towing Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 9319
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair
Sunroof / Moonroof Motor: Service and Repair
ROOF OPENING PANEL MOTOR
Removal
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Service and Repair/Roof Opening Panel Motor Initialization
1. Remove the headliner.
2. Disconnect the roof opening panel motor electrical connector and cut the tie strap.
3. Remove the roof opening panel motor.
- Remove the three bolts.
Installation
1. Connect the roof opening panel motor electrical connector. Install a new tie wrap and trim off
excess.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair > Page 9325
2. NOTE: When installing the roof opening panel motor/module, align the three attach holes before
engaging the drive gear into the roof opening
panel drive cable. Do not rotate the motor assembly after the drive gear is engaged with the roof
opening panel drive cable. Otherwise, the cable can bind.
Install the roof opening panel motor. Align the attach holes, then install the three bolts.
3. Connect the overhead console electrical connectors. 4. Initialize the roof opening panel
motor/module. 5. Disconnect the overhead console electrical connectors. 6. Install the headliner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9329
Sunroof / Moonroof Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9330
Sunroof / Moonroof Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9331
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair
Sunroof / Moonroof Track: Service and Repair
ROOF OPENING PANEL REAR TROUGH GUIDE
Removal and Installation
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including: whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Service and Repair/Roof Opening Panel Motor Initialization
1. Remove the roof opening panel.
2. Remove the two trough guide retaining screws.
3. Remove the trough from the trough guide assembly.
4. Disconnect the trough guide rods from the lifter arm assemblies.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Page 9335
5. Slide the trough guide back to the slot (approximately 15 mm (0.6 in)) cut in track.
6. Carefully twist trough guide through the slot in the track to remove. 7. Inspect the trough guide
assembly for damage. If damage is found, inspect the track for broken pieces and remove them. 8.
To install, reverse the removal procedure. 9. Adjust roof opening panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair
Sunroof / Moonroof Windguard: Service and Repair
AIR DEFLECTOR
Removal and Installation
1. Open the roof opening panel.
2. NOTE: RH side shown, LH is similar.
Remove the two air deflector tether screws.
3. Raise the front of the air deflector.
4. Slide the air deflector toward the rear, then lift up to release it from the pivot shafts. 5. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair
Sunroof / Moonroof Frame: Service and Repair
ROOF OPENING PANEL FRAME
Removal and Installation
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Service and Repair/Roof Opening Panel Motor Initialization
1. Remove the headliner.
2. Remove the overhead console bracket.
- Remove the screws.
3. Disconnect the electrical connector and cut the tie strap.
4. Remove the roof opening panel frame.
1 Disconnect the four roof opening panel drain hoses.
2 Remove the 11 bolts.
3 Remove the roof opening panel frame.
5. To install, reverse the removal procedure. If a new roof opening panel frame is being installed,
transfer the existing roof opening panel motor, air
deflector, rear trough, roof opening panel glass and roof opening panel shield onto the new frame
assembly. Initialize the roof opening panel motor. Refer to Roof Opening Panel Motor Initialization.
See: Service and Repair/Roof Opening Panel Motor Initialization
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 9345
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel
ROOF OPENING PANEL
Removal and Installation
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including: whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Service and Repair/Roof Opening Panel Motor Initialization
1. Position the roof opening panel in the vent position.
2. Remove the four roof opening panel bolts.
3. Remove the roof opening panel from the outside of the vehicle by lifting up and out. 4. To install,
reverse the removal procedure.
- Adjust the roof opening panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel > Page 9350
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield
ROOF OPENING PANEL SHIELD
Removal and Installation
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Service and Repair/Roof Opening Panel Motor Initialization
1. Remove the roof opening panel.
2. Remove the water trough.
1 Remove the screws.
2 Remove the water trough.
3. Flex the opening shield to remove the guides from the tracks and remove the roof opening panel
shield. 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash
Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High
Pressure Car Wash
TSB 08-24-8
12/08/08
WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH
FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition
LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT
This article supersedes TSB 08-1-4 to update the Part List and Service procedure.
ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008
Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear
of roof opening panel during a high pressure car wash.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT
1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner
or equivalent.
5. Remove the adhesive tape covering from trough seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 9359
6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal
lines up against front flange of trough. (Figures 1-3)
7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough.
8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining
screws and torque to 9 lb-in. (1 N.m)
9. Remove protective covering.
10. Install roof opening panel following WSM, Section 501-17.
2005-2009 Expedition / Navigator
1. Remove roof opening panel glass only. Refer to WSM, Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. Install new trough and seal assembly.
5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2)
trough guide retaining screws and torque to 9 lb-in. (1 N.m)
6. Remove protective covering.
7. Install roof opening panel following WSM, Section 501-17.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof
Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 9360
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082408A 2005-2009 Expedition, 0.5 Hr.
Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A)
082408A 2005-2008 F-Super Duty, 0.6 Hr.
F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use
With 5028A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502C50 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks
During High Pressure Car Wash
TSB 08-24-8
12/08/08
WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH
FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition
LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT
This article supersedes TSB 08-1-4 to update the Part List and Service procedure.
ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008
Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear
of roof opening panel during a high pressure car wash.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT
1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner
or equivalent.
5. Remove the adhesive tape covering from trough seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page
9366
6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal
lines up against front flange of trough. (Figures 1-3)
7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough.
8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining
screws and torque to 9 lb-in. (1 N.m)
9. Remove protective covering.
10. Install roof opening panel following WSM, Section 501-17.
2005-2009 Expedition / Navigator
1. Remove roof opening panel glass only. Refer to WSM, Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. Install new trough and seal assembly.
5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2)
trough guide retaining screws and torque to 9 lb-in. (1 N.m)
6. Remove protective covering.
7. Install roof opening panel following WSM, Section 501-17.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof
/ Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page
9367
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082408A 2005-2009 Expedition, 0.5 Hr.
Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A)
082408A 2005-2008 F-Super Duty, 0.6 Hr.
F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use
With 5028A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502C50 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 9368
Sunroof / Moonroof Weatherstrip: Service and Repair
ROOF OPENING PANEL WEATHERSTRIP
Removal
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including: whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Service and Repair/Roof Opening Panel Motor Initialization
1. Remove the roof opening panel. 2. Place roof opening panel, topside up, on a worktable. Take
care to support the glass assembly from below to prevent damaging the mounting tabs.
3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip.
Installation
1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the
passenger side. 2. Starting with the corners, push the weatherstrip into position. Continue pushing
the weatherstrip into position around the glass assembly until
complete. Use a plastic or rubber hammer if necessary.
3. Install the roof opening panel. 4. Adjust the roof panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9374
Memory Positioning Module: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9375
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9379
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9380
Seat Memory Switch: Testing and Inspection
SWITCH - MEMORY SET
Memory Set Switch
Remove the memory set switch.
Measure the resistance between the indicated terminals while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to
the calling pinpoint test.
NOTE: Refer to multimeter user's manual for testing diodes.
To check the memory set switch LED, connect the positive meter lead to terminal 7 and the
negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, install a new switch; otherwise, return to the
calling pinpoint test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Application
and ID
Power Seat Control Module: Application and ID
THIRD ROW POWER-FOLD SEAT
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move
Power Seat Motor: Customer Interest Interior - Driver's Power Seat Will Not Move
TSB 05-18-14
09/22/05
DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 05-9-4 to update the part information and Service Procedure.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 12/06/2004 with memory seats
may exhibit the driver's power seat binding in the full rearward position and becoming inoperative in
forward and reverse. This may be due to the horizontal seat motor and memory seat position
sensor (potentiometer) on vehicles built before 10/16/2003, or due to the potentiometer (only) on
vehicles built between 10/16/2003 and 12/05/2004.
ACTION If the vehicle was built before 10/16/2003, inspect the horizontal motor bracket under the
seat. If the bracket has bends on either side of the seat motor, install a horizontal seat motor kit. If
the vehicle already has a straight bracket, or if the vehicle was built between 10/16/2003 and
12/05/2004, install a seat potentiometer kit only. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
WHEN INSTALLING A MOTOR KIT, THE SEAT TRACK FRONT COVER MUST ALSO BE
REPLACED. THE ORIGINAL SEAT TRACK FRONT COVER WILL NOT FIT ON THE NEWER
MOTOR ASSEMBLY BEING INSTALLED.
NOTE
FOR 2003 NAVIGATOR VEHICLES EQUIPPED WITH A BLACK INTERIOR, ORDER THE DOVE
GRAY SEAT TRACK FRONT COVER AND PAINT TO MATCH (BLACK INK).
REMOVAL - SEAT MOTOR ASSEMBLY OR POTENTIOMETER
1. Position the driver seat all the way up.
2. Remove the seat track front cover.
3. Check vehicle build date.
a. If built between 10/16/2003 and 12/05/2004, only a potentiometer kit will need to be installed.
Proceed to Step 4.
b. If built before 10/16/2003, inspect the horizontal seat motor bracket (cross bar) to determine if a
motor kit is needed, or only a potentiometer kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9392
(1) If the horizontal seat motor bracket has bends (Figure 1) a motor kit will need to be installed.
Proceed to Step 4.
(2) If the horizontal seat motor bracket is straight (Figure 2) only a potentiometer kit will need to be
installed. Proceed to Step 4.
4. Depower the supplemental restraint system (SRS). For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
5. Remove the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
6. Loosen the four (4) bolts under the seat track (Figure 3).
7. Disconnect the driver seat module (DSM) 24-pin electrical connector.
CAUTION
DO NOT APPLY POWER TO THE DSM IN THE FOLLOWING STEPS, OR DAMAGE WILL
OCCUR.
8. Using a remote power supply, position the seat track off the rear stop to full forward position
using the following steps:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9393
a. Apply battery voltage to the DSM wiring harness connector at location 1 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 2 (Figure 4).
9. Using the remote power supply again, position the seat track between mid travel and 2" (50 mm)
from the rear stop using the following steps.
a. Apply battery voltage to the DSM wiring harness connector at location 2 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 1 (Figure 4).
10. Disconnect the remote power supply.
11. Tighten the four (4) bolts under the seat track (Figure 5).
12. Reconnect the DSM electrical connector.
13. Disconnect the horizontal seat motor and seat position sensor electrical connectors.
14. Separate the horizontal seat motor assembly from the seat track studs using the following
steps:
a. Cut the two (2) horizontal motor drive cable tie straps at the inboard and outboard seat tracks.
b. Remove the two (2) nuts.
c. Using a suitable tool, pry up on the side of the horizontal motor bracket near the mounting stud
and separate the bracket from the stud.
d. Separate the horizontal motor bracket from the stud on the other side.
15. Lift up on the horizontal motor and bracket assembly, remove the drive cable from each seat
track, and remove the horizontal motor and bracket assembly. If installing a motor kit, proceed to
Step 2 of "INSTALLATION". If installing a potentiometer kit, proceed to Step 16.
16. Make note of the seat position sensor alignment to the motor for installation, then remove the
horizontal motor inboard cable and seat position sensor. To remove the seat position sensor from
the motor, pull straight out to disengage the locking tab. Proceed to Step 1 of "INSTALLATION".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9394
INSTALLATION
NOTE
ONE END OF THE INBOARD DRIVE CABLE WILL HAVE A LONGER SQUARE DRIVE THAN
THE OTHER END. THIS IS DUE TO THE LONGER SQUARE DRIVE HAVING TO PASS
THROUGH THE SEAT POSITION SENSOR AND MOTOR.
CAUTION
WHEN INSTALLING A NEW SEAT POSITION SENSOR, DO NOT BEND THE OUTBOARD
DRIVE CABLE, AS IT WILL HAVE TO BE REUSED. BENDING THE OUTBOARD DRIVE CABLE
CAN CAUSE NOISE ISSUES.
1. Install the seat position sensor using the following steps:
a. Align the seat position sensor to the horizontal motor as noted during removal and push in on the
sensor to install.
b. Install the inboard cable with the longer square drive end going into the sensor and motor. Turn
the cable and push in to engage to motor.
2. Verify the cables are engaged into the motor by confirming there is resistance when turning the
cable.
3. Feed the inboard and outboard drive cables into the seat tracks. By rotating the horizontal motor
and bracket assembly, the cables can be engaged into the inboard and outboard seat tracks
(Figure 6).
4. Align the horizontal motor bracket to the seat tracks and slide down on the studs.
5. Install the nuts (Figure 7).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9395
6. Connect the motor and seat position sensor electrical connectors (Figure 8).
CAUTION
DOUBLE CHECK THAT ALL CONNECTORS TO DSM, MOTOR, AND POTENTIOMETER ARE
PROPERLY CONNECTED BEFORE ATTACHING MAIN BODY HARNESS. IF THE POWER
SEAT IS OPERATED WHILE THE POTENTIOMETER IS DISCONNECTED, LOSS OF SOFT
STOP FUNCTION IS LIKELY AND WILL RESULT IN THE NEED TO REPLACE THE DSM.
SYMPTOMS OF A DISCONNECTED POTENTIOMETER IS
FORWARD/REARWARD SEAT MOVEMENT FOR ONLY ONE (1) SECOND BEFORE AN
AUTOMATIC STOP.
7. Using a heat gun, shrink tube the inboard and outboard cable ends to the seat track and install a
tie strap at each seat track.
8. Install the seat track front cover.
9. Install the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
10. Repower the supplemental restraint system. For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
11. To set the soft stop position, function the seat forward to at least mid-travel and then rearward
all the way to the rearmost position. Allow the seat to hit the rear stops and continue holding the
switch until the seat module clicks off (approximately 1 second after hitting the rear stops). This will
set the soft stop position.
12. Verify soft stop function is working properly with the following steps:
a. Access vehicle message center and check that EZ-Exit/Entry is "ON".
b. Move seat forward approximately 1" (25 mm) from full rear.
c. Remove key from ignition.
d. Observe seat behavior. Seat should move backwards approximately 1/2" to 3/4" (12 to 19 mm)
and stop.
e. Activate seat switch rearward, seat should still have 1/4" to 1/2" (6 to 12 mm) of travel to full rear.
f. If no movement observed in Step d, move seat slightly further forward and repeat Steps c
through e. If there is still no movement observed in Step d, replace the DSM per procedures in
Workshop Manual Section 419-10.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9396
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051814A 2003-2005 Expedition, 1.2 Hrs.
2004-2005 Navigator: Replace Horizontal Seat Motor Kit Or Potentiometer, Includes Time To
Install Seat Track Front Cover (Do Not Use With 14718A, 14547A)
051814B 2003 Navigator: Replace 1.3 Hrs.
Horizontal Seat Motor Kit Or Potentiometer Includes Time To Paint And Install Seat Track Front
Cover (Do Not Use With 14718A, 14547A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14547 41
OASIS CODES: 101000
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move
Power Seat Motor: All Technical Service Bulletins Interior - Driver's Power Seat Will Not Move
TSB 05-18-14
09/22/05
DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 05-9-4 to update the part information and Service Procedure.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 12/06/2004 with memory seats
may exhibit the driver's power seat binding in the full rearward position and becoming inoperative in
forward and reverse. This may be due to the horizontal seat motor and memory seat position
sensor (potentiometer) on vehicles built before 10/16/2003, or due to the potentiometer (only) on
vehicles built between 10/16/2003 and 12/05/2004.
ACTION If the vehicle was built before 10/16/2003, inspect the horizontal motor bracket under the
seat. If the bracket has bends on either side of the seat motor, install a horizontal seat motor kit. If
the vehicle already has a straight bracket, or if the vehicle was built between 10/16/2003 and
12/05/2004, install a seat potentiometer kit only. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
WHEN INSTALLING A MOTOR KIT, THE SEAT TRACK FRONT COVER MUST ALSO BE
REPLACED. THE ORIGINAL SEAT TRACK FRONT COVER WILL NOT FIT ON THE NEWER
MOTOR ASSEMBLY BEING INSTALLED.
NOTE
FOR 2003 NAVIGATOR VEHICLES EQUIPPED WITH A BLACK INTERIOR, ORDER THE DOVE
GRAY SEAT TRACK FRONT COVER AND PAINT TO MATCH (BLACK INK).
REMOVAL - SEAT MOTOR ASSEMBLY OR POTENTIOMETER
1. Position the driver seat all the way up.
2. Remove the seat track front cover.
3. Check vehicle build date.
a. If built between 10/16/2003 and 12/05/2004, only a potentiometer kit will need to be installed.
Proceed to Step 4.
b. If built before 10/16/2003, inspect the horizontal seat motor bracket (cross bar) to determine if a
motor kit is needed, or only a potentiometer kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9402
(1) If the horizontal seat motor bracket has bends (Figure 1) a motor kit will need to be installed.
Proceed to Step 4.
(2) If the horizontal seat motor bracket is straight (Figure 2) only a potentiometer kit will need to be
installed. Proceed to Step 4.
4. Depower the supplemental restraint system (SRS). For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
5. Remove the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
6. Loosen the four (4) bolts under the seat track (Figure 3).
7. Disconnect the driver seat module (DSM) 24-pin electrical connector.
CAUTION
DO NOT APPLY POWER TO THE DSM IN THE FOLLOWING STEPS, OR DAMAGE WILL
OCCUR.
8. Using a remote power supply, position the seat track off the rear stop to full forward position
using the following steps:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9403
a. Apply battery voltage to the DSM wiring harness connector at location 1 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 2 (Figure 4).
9. Using the remote power supply again, position the seat track between mid travel and 2" (50 mm)
from the rear stop using the following steps.
a. Apply battery voltage to the DSM wiring harness connector at location 2 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 1 (Figure 4).
10. Disconnect the remote power supply.
11. Tighten the four (4) bolts under the seat track (Figure 5).
12. Reconnect the DSM electrical connector.
13. Disconnect the horizontal seat motor and seat position sensor electrical connectors.
14. Separate the horizontal seat motor assembly from the seat track studs using the following
steps:
a. Cut the two (2) horizontal motor drive cable tie straps at the inboard and outboard seat tracks.
b. Remove the two (2) nuts.
c. Using a suitable tool, pry up on the side of the horizontal motor bracket near the mounting stud
and separate the bracket from the stud.
d. Separate the horizontal motor bracket from the stud on the other side.
15. Lift up on the horizontal motor and bracket assembly, remove the drive cable from each seat
track, and remove the horizontal motor and bracket assembly. If installing a motor kit, proceed to
Step 2 of "INSTALLATION". If installing a potentiometer kit, proceed to Step 16.
16. Make note of the seat position sensor alignment to the motor for installation, then remove the
horizontal motor inboard cable and seat position sensor. To remove the seat position sensor from
the motor, pull straight out to disengage the locking tab. Proceed to Step 1 of "INSTALLATION".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9404
INSTALLATION
NOTE
ONE END OF THE INBOARD DRIVE CABLE WILL HAVE A LONGER SQUARE DRIVE THAN
THE OTHER END. THIS IS DUE TO THE LONGER SQUARE DRIVE HAVING TO PASS
THROUGH THE SEAT POSITION SENSOR AND MOTOR.
CAUTION
WHEN INSTALLING A NEW SEAT POSITION SENSOR, DO NOT BEND THE OUTBOARD
DRIVE CABLE, AS IT WILL HAVE TO BE REUSED. BENDING THE OUTBOARD DRIVE CABLE
CAN CAUSE NOISE ISSUES.
1. Install the seat position sensor using the following steps:
a. Align the seat position sensor to the horizontal motor as noted during removal and push in on the
sensor to install.
b. Install the inboard cable with the longer square drive end going into the sensor and motor. Turn
the cable and push in to engage to motor.
2. Verify the cables are engaged into the motor by confirming there is resistance when turning the
cable.
3. Feed the inboard and outboard drive cables into the seat tracks. By rotating the horizontal motor
and bracket assembly, the cables can be engaged into the inboard and outboard seat tracks
(Figure 6).
4. Align the horizontal motor bracket to the seat tracks and slide down on the studs.
5. Install the nuts (Figure 7).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9405
6. Connect the motor and seat position sensor electrical connectors (Figure 8).
CAUTION
DOUBLE CHECK THAT ALL CONNECTORS TO DSM, MOTOR, AND POTENTIOMETER ARE
PROPERLY CONNECTED BEFORE ATTACHING MAIN BODY HARNESS. IF THE POWER
SEAT IS OPERATED WHILE THE POTENTIOMETER IS DISCONNECTED, LOSS OF SOFT
STOP FUNCTION IS LIKELY AND WILL RESULT IN THE NEED TO REPLACE THE DSM.
SYMPTOMS OF A DISCONNECTED POTENTIOMETER IS
FORWARD/REARWARD SEAT MOVEMENT FOR ONLY ONE (1) SECOND BEFORE AN
AUTOMATIC STOP.
7. Using a heat gun, shrink tube the inboard and outboard cable ends to the seat track and install a
tie strap at each seat track.
8. Install the seat track front cover.
9. Install the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
10. Repower the supplemental restraint system. For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
11. To set the soft stop position, function the seat forward to at least mid-travel and then rearward
all the way to the rearmost position. Allow the seat to hit the rear stops and continue holding the
switch until the seat module clicks off (approximately 1 second after hitting the rear stops). This will
set the soft stop position.
12. Verify soft stop function is working properly with the following steps:
a. Access vehicle message center and check that EZ-Exit/Entry is "ON".
b. Move seat forward approximately 1" (25 mm) from full rear.
c. Remove key from ignition.
d. Observe seat behavior. Seat should move backwards approximately 1/2" to 3/4" (12 to 19 mm)
and stop.
e. Activate seat switch rearward, seat should still have 1/4" to 1/2" (6 to 12 mm) of travel to full rear.
f. If no movement observed in Step d, move seat slightly further forward and repeat Steps c
through e. If there is still no movement observed in Step d, replace the DSM per procedures in
Workshop Manual Section 419-10.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9406
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051814A 2003-2005 Expedition, 1.2 Hrs.
2004-2005 Navigator: Replace Horizontal Seat Motor Kit Or Potentiometer, Includes Time To
Install Seat Track Front Cover (Do Not Use With 14718A, 14547A)
051814B 2003 Navigator: Replace 1.3 Hrs.
Horizontal Seat Motor Kit Or Potentiometer Includes Time To Paint And Install Seat Track Front
Cover (Do Not Use With 14718A, 14547A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14547 41
OASIS CODES: 101000
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Power Seat Motor: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle
Condition
Transmission Mount: All Technical Service Bulletins Engine Controls - Cold Start Rough Idle
Condition
TSB 06-5-1
03/20/06
COLD START ROUGH IDLE EXPEDITION 4X2 ONLY
FORD: 2005-2006 Expedition
ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at
1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle
when the engine is first started after being off for an extended period of time in warm weather in
excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C).
The issue is not typically accompanied by unusual engine or fan noise. It is independent of air
conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump
operation (audible hum or buzz accompanied by an associated vibration).
ACTION Use the following Service Procedure to resolve the concern.
SERVICE PROCEDURE
1. Using normal Workshop Manual diagnostics:
a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as
necessary.
b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as
necessary.
2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as
necessary.
3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher.
This new calibration is not included in the B42 CD. Calibration files may also be obtained at the
website.
NOTE
COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL
INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE
ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE
ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION.
4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section
303-01 - Engine Support Insulators
5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission
Insulator & Retainer
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount,
Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84,
050415A,
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Power Seat Motor: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle
Condition > Page 9412
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Power Seat Motor: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle
Condition > Page 9418
052301A)
060501B 2006 Expedition 4X2: 3.6 Hrs.
Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control
Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A)
MT060501 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9421
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9422
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9423
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9424
Power Seat Motor: Locations
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9425
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9426
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9427
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9428
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9429
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9430
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9431
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9432
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9433
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9434
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third
Row Folding Seat Motor, Left > Page 9435
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9438
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9439
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9440
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9441
Power Seat Motor: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9442
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9443
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9444
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9445
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams >
Passenger Seat Horizontal Motor > Page 9446
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor
Power Seat Motor: Service and Repair Front Seat Track Motor
FRONT SEAT TRACK MOTOR
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All motors 1. Remove the 40 percent seat and depower the SRS.
Forward/Reverse motor
2. NOTE: If equipped with memory seat, disconnect the memory seat motor sensor electrical
connector and remove sensor from the motor.
Remove the forward/reverse motor. 1
Disconnect the electrical connector.
2 Pull to release the power seat drive cables from the motor.
3 Remove the four screws (two shown).
4 Remove the power seat motor.
Rear height motor
3. NOTE: If equipped with memory seat, disconnect the memory seat motor sensor electrical
connector and remove sensor from the motor.
Remove the rear height motor. 1
Disconnect the rear height motor electrical connector.
2 Remove the roll pin.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9449
3 Remove the bolt and nut.
4 Remove the rear height power seat motor.
Front height motor 4. If equipped, remove the temperature controlled seat fan motor.
5. NOTE: If equipped with memory seat, disconnect the memory seat motor sensor electrical
connector and remove sensor from the motor.
Remove the front height motor. 1
Disconnect the front height motor electrical connector.
2 Remove the roll pin.
3 Remove the roll pin.
4 Remove the front height power seat motor.
Installation
Front height motor
1. NOTE: If equipped with memory seat, install the sensor to the motor and connect the memory
seat motor sensor electrical connector.
Install the front height motor. 1
Install the front height motor.
2 Install the roll pin.
3 Install the roll pin.
4 Connect the front height motor electrical connector.
2. If equipped, install the temperature controlled seat fan motor.
Rear height motor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9450
3. NOTE: If equipped with memory seat, install sensor to the motor and connect the memory seat
motor sensor electrical connector.
Install the rear height motor. 1
Install the rear power seat motor.
2 Install the bolt and nut.
3 Install the roll pin.
4 Connect the rear height motor electrical connector.
Forward/Reverse motor
4. NOTE: If equipped with memory seat, install sensor to the motor and connect the memory seat
motor sensor electrical connector.
Install the forward/reverse motor. 1
Install the forward/reverse power seat motor.
2 Install the four screws (two shown).
3 Install the power seat motor cables.
4 Connect the forward/reverse motor electrical connector.
All motors 5. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9451
Power Seat Motor: Service and Repair Front Seat Recliner Motor
FRONT SEAT RECLINER MOTOR
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Remove lower seat backrest cover.
3. Remove the two screws from support rod.
4. Release the one hook-and-loop strip and the one J-clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9452
5. Depress tab and remove the head restraint.
6. NOTE: The head restraint sleeve pins are not interchangeable. Note location for installation.
Reach up into seat backrest and squeeze the head restraint sleeve ends together to release the
sleeves, and pull the head restraint sleeves out.
7. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat backrest foam.
Invert the seat backrest trim cover and remove.
8. CAUTION: Use care when removing the seat backrest foam pad from the frame. The foam pad
has hook and loop fasteners holding the
thermo-electric device to the seat backrest foam pad.
Remove the seat backrest foam pad from the thermo-electric device and remove the seat backrest
foam pad.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9453
9. Remove the retainer clip on the end of the power recliner motor shaft.
10. Remove the power recliner motor shaft.
1 Remove the power recliner motor shaft cover.
2 Slide the power recliner motor shaft out from the power recliner motor.
11. Remove the power recliner motor.
1 Disconnect the power recliner motor electrical connector.
2 Remove the power recliner motor bolt.
3 Remove the power recliner motor.
Installation
1. Install the power recliner motor.
1 Install the power recliner motor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9454
2 Install the power recliner motor bolt.
3 Connect the power recliner motor electrical connector.
2. Install the power recliner shaft.
1 Slide the power recliner shaft into the motor and through the seat.
2 Install the power recliner shaft cover.
3. Install the retainer clip onto the end of the power recliner shaft.
4. Install the seat backrest foam pad and attach the seat backrest thermo-electric device to the
foam pad. 5. Install the seat backrest trim cover and attach the hook-and-loop fasteners.
6. NOTE: The head restraint sleeve pins are not interchangeable.
Install the head restraint sleeves.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9455
7. Install the head restraint.
8. Connect the one hook-and-loop strip and the one J-clip.
9. Install the two screws in support rod.
10. Install the lower backrest cover. 11. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9456
Power Seat Motor: Service and Repair Lumbar Motor
LUMBAR MOTOR
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Remove lower seat backrest cover.
3. Remove the two screws from support rod.
4. Release the one hook-and-loop strip and the one J-clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9457
5. Depress tab and remove the head restraint.
6. NOTE: The head restraint sleeve pins are not interchangeable. Note location for installation.
Reach up into seat backrest and squeeze the head restraint sleeve ends together to release the
sleeves and pull the head restraint sleeves out.
7. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat backrest foam.
Invert the seat backrest trim cover and remove.
8. CAUTION: Use care when removing the seat backrest foam pad from the frame. The foam pad
has hook-and-loop fasteners holding the
thermo-electric device to the seat backrest foam pad.
NOTE: Remove the seat backrest foam pad from the thermo-electric device (TED) and remove the
seat backrest foam pad.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9458
9. Remove the screws from the lumbar motor support cover and remove support cover (two
shown).
10. Remove the lumbar motor cable from the lumbar support.
1 Flex the lumbar support.
2 Separate the lumbar support adjusting cable from the positioning spring.
3 Unhook the lumbar support adjusting cable from the lumbar support.
11. Remove the staples and open dampening bag.
12. Remove the power lumbar support motor.
1 Disconnect the power lumbar motor electrical connector.
2 Remove the screws.
3 Remove the power lumbar support motor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9459
Installation
1. Install the power lumbar support motor.
1 Install the dampening bag and install the power lumbar support motor.
2 Install the screws.
3 Connect the power lumbar electrical connector.
2. Close the dampening bag and staple.
3. Install the lumbar motor cable to the lumbar support.
1 Hook the lumbar support adjusting cable to the lumbar support.
2 Flex the lumbar support.
3 Install the lumbar support adjusting cable to the positioning spring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9460
4. Install the lumbar motor support cover and install the screws for the support cover (two shown).
5. Install the seat backrest foam pad and attach the seat backrest TED to the foam pad. 6. Install
the seat backrest trim cover and attach the hook-and-loop fasteners to the foam pad.
7. NOTE: The head restraint sleeve pins are not interchangeable.
Install the head restraint sleeves.
8. Install the head restraint.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9461
9. Connect the one hook-and-loop strip and the one J-clip.
10. Install the two screws in the support rod.
11. Install the lower backrest cover. 12. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9462
Power Seat Motor: Service and Repair Power-Fold Seat Motor
POWER-FOLD SEAT MOTOR
Removal and Installation
CAUTION:
- To prevent possible damage to the third row seat or the safety belts, make sure that the safety
belts are not fastened when moving the seat to the load floor position.
- Make sure that no objects such as books, purses or briefcases are on the floor in front of the third
row seats or on the seat cushion before lowering the backrest(s).
NOTE:
- The third row seat backrests need to be in the raised position for removal of the third row seats.
- A cable assembly service kit is available.
- 60 percent seat shown, 40 percent similar.
All vehicles
1. Remove the rear load floor panel.
2. Remove the jack assembly.
3. Remove the load floor panel latch striker bolts and latch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9463
4. Remove the three pin-type retainers (one shown) and the jack storage compartment liner.
5. Remove the two bolts in mid-floor support (one shown). 6. Lift on the front of the mid-floor panel
support to release the three retainer clips and remove the support panel.
Vehicles with inoperative motor, backrest in down position
7. Using a suitable tool, insert it in the outboard side of the third row power seat motor. Raise the
seat backrest.
Vehicles with inoperative motor or driver cable damaged, backrest in down position
8. Cut and remove the power seat drive cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9464
9. Using a suitable tool, insert it into the drive gear assembly and raise the seat backrest.
All vehicles 10. Remove the affected third row seat.
All seats
11. Position the inboard side shield out of the way.
1 Lift the cushion up.
2 Remove the screw.
3 Slide the side shield up and out of the way.
12. Separate the parts from the power-fold seat motor bracket.
1 Remove the bolt and separate the safety belt anchor.
2 Remove the nut from the inboard slide bracket.
3 Separate the inboard slide bracket from the power-fold seat motor bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Front Seat Track Motor > Page 9465
13. Remove the 2 bolts and the power-fold seat motor assembly.
14. NOTE: The motor should only need to be removed when installing a cable assembly service kit.
To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9470
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9471
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9472
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9473
Power Seat Motor Position Sensor: Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9474
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9475
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9476
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9477
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Locations > Driver Memory Seat Recliner Sensor > Page 9478
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Diagrams > Driver Memory Seat Horizontal Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Diagrams > Driver Memory Seat Horizontal Sensor > Page 9481
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Diagrams > Driver Memory Seat Horizontal Sensor > Page 9482
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Diagrams > Driver Memory Seat Horizontal Sensor > Page 9483
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Diagrams > Driver Memory Seat Horizontal Sensor > Page 9484
Power Seat Motor Position Sensor: Diagrams Height Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information >
Diagrams > Driver Memory Seat Horizontal Sensor > Page 9485
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third
Row Folding Seat Relay, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third
Row Folding Seat Relay, Left > Page 9491
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 9494
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 9495
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 9496
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9501
Power Seat Switch: Locations Power Seat Switch
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9502
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch
Power Seat Switch: Diagrams Power Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch > Page 9505
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch > Page 9506
Power Seat Switch: Diagrams Third Row Folding Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch
Power Seat Switch: Testing and Inspection Power Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9509
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9510
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9511
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9512
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9513
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9514
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9515
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9516
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9517
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9518
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9519
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9520
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9521
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9522
Power Seat Switch: Testing and Inspection Third Row Folding Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9523
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9524
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch > Page 9525
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way
Power Seat Switch: Service and Repair Seat Control Switch - 8-Way
SEAT CONTROL SWITCH - 8-WAY
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver side shown, passenger side similar.
1. Remove the affected seat and depower the SRS.
2. Pry to remove the two power seat knobs and remove the knobs.
3. Access and remove the front side shield screw.
4. Pull out from the bottom and rear side of side shield to release the three retainer clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9528
5. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors.
6. Remove the three screws and remove the power seat switch.
Installation
1. Install the power seat switch and install the three screws.
2. Connect the 8-way power seat and power lumbar switch electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9529
3. Push to install the three side shield retainers onto the seat frame.
4. Access and install the front side shield screw.
5. Install the two power seat knobs. 6. Install the affected seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9530
Power Seat Switch: Service and Repair Seat Control Switch - 6-Way
SEAT CONTROL SWITCH - 6-WAY
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver seat is shown, passenger is similar.
1. Remove the affected seat and depower the SRS.
2. Disconnect the 6-way power seat switch electrical connector.
3. Remove the recliner handle screw cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9531
4. Remove the recliner handle screw and the recliner handle.
5. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure
on both sides of the knob to remove.
Pull out to remove the lumbar knob.
6. Remove the screw from the side shield under the lumbar knob.
7. CAUTION: Use care not to scratch the side shield when removing the power seat knob.
Pry the power seat knob off.
8. Access and remove the front side shield screw.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9532
9. Pull to release the center retainer on side shield.
10. Pull to release the retainer clip on the rear of side shield. 11. Remove the side shield from the
seat.
12. Remove the two screws and remove the 6-way power seat switch from the side shield.
Installation
1. Install the 6-way power seat switch on the side shield and install the two screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9533
2. Push to install the rear side shield retainer on seat frame.
3. Push to install the middle side shield retainer on the seat.
4. Access and install the front side shield screw.
5. Install the 6-way power seat knob.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9534
6. Install the screw on the side shield under the lumbar knob.
7. Align and install the lumbar knob.
8. Install the recliner handle and install the screw.
9. Install the recliner handle cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9535
10. Connect the 6-way power seat switch electrical connector. 11. Install the affected seat and
repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Seat Control Switch - 8-Way > Page 9536
Power Seat Switch: Service and Repair Seat Control Switch - Third Row
SEAT CONTROL SWITCH - THIRD ROW
Removal and Installation
1. Partially remove the RH quarter trim panel for access to the third row power seat switch(es). 2.
Remove the retainer nuts on the back side of the power seat switch housing.
3. Disconnect the power seat switch electrical connectors.
4. Release the four locking tabs (two shown) on the affected switch, and remove the switch. 5. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent
Seat Cushion: Service and Repair Front Seat Cushion - 40 Percent
FRONT SEAT CUSHION - 40 PERCENT
Disassembly
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Remove the 40 percent seat and depower the SRS. 2. Remove the side shield.
3. Release the J-clips on the pivot covers (inboard shown, outboard similar).
4. Release the J-clips (six shown).
5. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion.
Remove the seat cushion cover.
6. Remove the seat cushion foam pad.
Vehicles with power seats 7. Remove the power seat motors. 8. Remove the power seat tracks.
Vehicles with manual seat 9. Remove the manual seat track.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9541
Vehicles with manual lumbar
10. Remove the front seat back lumbar adjuster.
1 Remove the two screws.
2 Remove the front seat back lumbar adjuster.
11. NOTE: The lumbar support assembly must be fully relaxed.
Separate the lumbar support adjuster from the adjuster cable.
Vehicles with memory seats
12. NOTE: The inset shows the driver seat module (DSM) retaining bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9542
Remove the DSM. 1
Pull the back of the DSM away from the seat and slide it off the mounting bracket.
2 Disconnect the electrical connectors.
3 Remove the DSM.
Vehicles with climate controlled seats 13. Remove the seat fan motor. 14. Remove the climate
controlled seat module. 15. Remove the seat cushion thermo-electric device. 16. Remove the
climate controlled seat cushion ducts. 17. Unclip and remove the TED mounting bezel.
Assembly
Vehicles with climate controlled seats 1. Clip the TED mounting bezel to the seat cushion support.
2. Install the climate controlled seat cushion ducts. 3. Install the seat cushion thermo-electric
device. 4. Install the climate controlled seat module. 5. Install the seat fan motor.
Vehicles with memory seats
6. Connect the memory seat module electrical connectors and install the memory seat module. 7.
Slide the memory seat module onto the seat frame bracket.
Vehicles with manual lumbar
8. Connect the lumbar support adjuster from the adjuster cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9543
9. Install the front seat back lumbar adjuster.
1 Install the front seat back lumbar adjuster.
2 Install the two screws.
Vehicles with manual seat 10. Install the manual seat track.
Vehicles with power seats 11. Install the power seat tracks. 12. Install the power seat motors.
All vehicles 13. Install the seat cushion foam pad. 14. Install the seat cushion cover.
15. Attach the J-clips (six shown).
16. Install the J-clips on the pivot covers (inboard shown, outboard similar). 17. Install the side
shield. 18. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9544
Seat Cushion: Service and Repair Front Seat Cushion - 60 Percent
FRONT SEAT CUSHION - 60 PERCENT
Disassembly
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 60 percent seat and depower the SRS. 2. Remove the 60 percent seat backrest.
3. Remove the inner side shield.
4. Remove the two side shield screws.
5. Release the front seat cushion cover J-clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9545
6. Remove the two recliner bolts.
7. Remove the bolts. 8. Remove the seat track.
9. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Invert the seat cushion cover and remove from the cushion foam pad.
10. Remove the front seat cushion foam pad from the front seat cushion frame.
Assembly
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9546
1. Insert the front seat cushion foam pad into the front seat cushion frame.
2. Install the seat cushion cover on the seat cushion foam pad. 3. Install the seat track.
4. Install the bolts.
5. Install the recliner bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9547
6. Fasten the seat cushion cover J-clips.
7. Install the two screws in the side shield.
8. Install the inner side shield. 9. Install the 60 percent seat backrest.
10. Install the 60 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9548
Seat Cushion: Service and Repair Rear Seat Cushion - Second Row, 40 Percent
REAR SEAT CUSHION - SECOND ROW, 40 PERCENT
Disassembly and Assembly
1. Remove the 40 percent seat backrest.
2. Unsnap the pull strap retainer.
3. Release the four J-clips (two shown). 4. Remove the seat cushion cover and cushion foam pad
from the seat cushion frame.
5. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Remove the seat cushion cover from the seat cushion foam pad.
6. Remove the three pin-type retainers from the seat bottom cover (two shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9549
7. Release the two J-clips for the bottom cover.
8. Remove the four pin-type retainers from the sides of bottom cover (two shown). 9. Remove the
bottom cover.
10. Remove the seat belt buckle bolt and remove the seat belt buckle.
- To aid installation, note the location of locating tab.
11. To assemble, reverse the disassembly procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9550
Seat Cushion: Service and Repair Rear Seat Cushion - Second Row, 20 Percent
REAR SEAT CUSHION - SECOND ROW, 20 PERCENT
Disassembly and Assembly
1. Remove the 20 percent seat backrest.
2. Release the J-clip.
3. Remove the two seat riser-to-cushion bolts.
4. Release the J-clips. 5. Remove the seat cushion frame from the foam pad.
6. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Remove the seat cushion cover from the foam pad.
7. To assemble, reverse the disassembly procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9551
Seat Cushion: Service and Repair
Front Seat Cushion - 40 Percent
FRONT SEAT CUSHION - 40 PERCENT
Disassembly
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Remove the 40 percent seat and depower the SRS. 2. Remove the side shield.
3. Release the J-clips on the pivot covers (inboard shown, outboard similar).
4. Release the J-clips (six shown).
5. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion.
Remove the seat cushion cover.
6. Remove the seat cushion foam pad.
Vehicles with power seats 7. Remove the power seat motors. 8. Remove the power seat tracks.
Vehicles with manual seat
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9552
9. Remove the manual seat track.
Vehicles with manual lumbar
10. Remove the front seat back lumbar adjuster.
1 Remove the two screws.
2 Remove the front seat back lumbar adjuster.
11. NOTE: The lumbar support assembly must be fully relaxed.
Separate the lumbar support adjuster from the adjuster cable.
Vehicles with memory seats
12. NOTE: The inset shows the driver seat module (DSM) retaining bracket.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9553
Remove the DSM. 1
Pull the back of the DSM away from the seat and slide it off the mounting bracket.
2 Disconnect the electrical connectors.
3 Remove the DSM.
Vehicles with climate controlled seats 13. Remove the seat fan motor. 14. Remove the climate
controlled seat module. 15. Remove the seat cushion thermo-electric device. 16. Remove the
climate controlled seat cushion ducts. 17. Unclip and remove the TED mounting bezel.
Assembly
Vehicles with climate controlled seats 1. Clip the TED mounting bezel to the seat cushion support.
2. Install the climate controlled seat cushion ducts. 3. Install the seat cushion thermo-electric
device. 4. Install the climate controlled seat module. 5. Install the seat fan motor.
Vehicles with memory seats
6. Connect the memory seat module electrical connectors and install the memory seat module. 7.
Slide the memory seat module onto the seat frame bracket.
Vehicles with manual lumbar
8. Connect the lumbar support adjuster from the adjuster cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9554
9. Install the front seat back lumbar adjuster.
1 Install the front seat back lumbar adjuster.
2 Install the two screws.
Vehicles with manual seat 10. Install the manual seat track.
Vehicles with power seats 11. Install the power seat tracks. 12. Install the power seat motors.
All vehicles 13. Install the seat cushion foam pad. 14. Install the seat cushion cover.
15. Attach the J-clips (six shown).
16. Install the J-clips on the pivot covers (inboard shown, outboard similar). 17. Install the side
shield. 18. Install the 40 percent seat and repower the SRS.
Front Seat Cushion - 60 Percent
FRONT SEAT CUSHION - 60 PERCENT
Disassembly
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9555
could result in pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 60 percent seat and depower the SRS. 2. Remove the 60 percent seat backrest.
3. Remove the inner side shield.
4. Remove the two side shield screws.
5. Release the front seat cushion cover J-clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9556
6. Remove the two recliner bolts.
7. Remove the bolts. 8. Remove the seat track.
9. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Invert the seat cushion cover and remove from the cushion foam pad.
10. Remove the front seat cushion foam pad from the front seat cushion frame.
Assembly
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9557
1. Insert the front seat cushion foam pad into the front seat cushion frame.
2. Install the seat cushion cover on the seat cushion foam pad. 3. Install the seat track.
4. Install the bolts.
5. Install the recliner bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9558
6. Fasten the seat cushion cover J-clips.
7. Install the two screws in the side shield.
8. Install the inner side shield. 9. Install the 60 percent seat backrest.
10. Install the 60 percent seat and repower the SRS.
Rear Seat Cushion - Second Row, 40 Percent
REAR SEAT CUSHION - SECOND ROW, 40 PERCENT
Disassembly and Assembly
1. Remove the 40 percent seat backrest.
2. Unsnap the pull strap retainer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9559
3. Release the four J-clips (two shown). 4. Remove the seat cushion cover and cushion foam pad
from the seat cushion frame.
5. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Remove the seat cushion cover from the seat cushion foam pad.
6. Remove the three pin-type retainers from the seat bottom cover (two shown).
7. Release the two J-clips for the bottom cover.
8. Remove the four pin-type retainers from the sides of bottom cover (two shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9560
9. Remove the bottom cover.
10. Remove the seat belt buckle bolt and remove the seat belt buckle.
- To aid installation, note the location of locating tab.
11. To assemble, reverse the disassembly procedure.
Rear Seat Cushion - Second Row, 20 Percent
REAR SEAT CUSHION - SECOND ROW, 20 PERCENT
Disassembly and Assembly
1. Remove the 20 percent seat backrest.
2. Release the J-clip.
3. Remove the two seat riser-to-cushion bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9561
4. Release the J-clips. 5. Remove the seat cushion frame from the foam pad.
6. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Remove the seat cushion cover from the foam pad.
7. To assemble, reverse the disassembly procedure.
Rear Seat Cushion - Third Row, 40 Percent
REAR SEAT CUSHION - THIRD ROW, 40 PERCENT
Disassembly and Assembly
1. Remove the third row 40 percent seat backrest.
2. Remove the nut from slide bracket from both sides of the seat cushion.
3. Remove the bolts from seat riser to cushion.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9562
4. Release the J-clips. 5. Remove the frame from the seat cushion foam.
6. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip,
or the hook and loop strip can be torn
from the seat cushion foam.
Remove the cushion trim cover from the foam pad.
7. To assemble, reverse the disassembly procedure.
Rear Seat Cushion - Third Row, 60 Percent
REAR SEAT CUSHION - THIRD ROW, 60 PERCENT
Disassembly and Assembly
1. Remove the third row 60 percent seat backrest.
2. Remove the nut from the slide bracket on both sides of the seat cushion.
3. Remove the bolts from seat riser to cushion.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion - 40 Percent > Page 9563
4. Release the J-clips. 5. Remove the frame from the seat cushion foam.
6. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion foam.
Remove the cushion trim cover from the foam pad.
7. To assemble, reverse the disassembly procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative
Seat Heater: Customer Interest A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative > Page 9572
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9577
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9578
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9579
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9580
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9581
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9582
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9583
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9584
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9585
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
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9586
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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> Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9587
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative
Seat Heater: All Technical Service Bulletins A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative > Page 9593
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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B272D > Page 9598
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9599
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9600
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9601
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9604
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9605
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9606
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9607
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9608
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions
Seat Heater: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9611
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9612
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9613
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9614
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9615
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9616
Symbols and Wire Color Code Identification
Symbols Part 1
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9617
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9618
Symbols Part 3
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9619
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9620
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9621
Seat Heater: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9622
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9623
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9624
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9625
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9626
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9627
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9628
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9629
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9630
Seat Heater: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9631
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9632
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9633
Seat Heater: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9634
119-2
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device
Seat Heater: Service and Repair Seat Backrest Thermo-Electric Device
SEAT BACKREST THERMO-ELECTRIC DEVICE
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Disconnect the seat backrest thermo-electric device (TED) electrical connector at the seat
cushion frame.
3. Remove lower seat backrest cover.
4. Remove the two screws from support rod.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9637
5. Release the one hook-and-loop strip and the one J-clip.
6. Depress tab and remove the head restraint.
7. NOTE: The head restraint sleeve pins are not interchangeable. Note location for installation.
Reach up into the seat backrest and squeeze the head restraint sleeve ends together to release
the sleeves and pull the head restraint sleeves out.
8. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat backrest foam.
Invert the seat backrest trim cover and remove.
9. CAUTION: Use care when removing the seat backrest foam pad from the frame. The foam pad
has hook and loop fasteners holding the
TED to the seat backrest foam pad.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9638
Remove the seat backrest foam pad from the TED and remove the seat backrest foam pad.
10. Route the seat backrest TED wire harness back through the seat cushion and trim cover.
11. Remove the seat backrest TED.
1 Remove the seat backrest TED wire harness pin-type retainers.
2 Cut the zip-ties and separate the ducts from the seat backrest TED.
3 Remove the seat backrest TED.
Installation
1. Install the seat backrest TED.
1 Install the seat backrest TED.
2 Install the seat backrest TED to the ducts and install the zip-ties.
3 Attach the pin-type retainer for the seat backrest TED wire harness.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9639
2. Route the seat backrest TED wire harness through the seat cushion and trim cover.
3. Install the seat backrest foam pad and attach the seat backrest TED to the foam pad. 4. Install
the seat backrest trim cover and attach the hook and loop fasteners.
5. NOTE: The head restraint sleeve pins are not interchangeable.
Install the head restraint sleeves.
6. Install the head restraint.
7. Connect the one hook-and-loop strip and the one J-clip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9640
8. Install the two screws in support rod.
9. Install the lower backrest cover.
10. Connect the seat backrest TED electrical connector. 11. Install the 40 percent seat and
repower the SRS.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9641
Seat Heater: Service and Repair Seat Cushion Thermo-Electric Device
SEAT CUSHION THERMO-ELECTRIC DEVICE
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS. 2. Remove the seat side shield. 3. Remove
the seat fan motor. 4. Remove the front height power seat motor.
5. Release the J-clips (six shown).
6. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip can be torn
from the seat cushion.
Remove the seat cushion trim cover.
7. Remove the seat cushion foam pad.
8. Remove the screw and separate the seat cushion thermo-electric device (TED) from the
mounting bezel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9642
9. Remove the seat cushion TED.
1 Cut the zip-tie, separate and remove the duct.
2 Disconnect the seat cushion TED electrical connector.
3 Remove the seat cushion TED.
Installation
1. Install the seat cushion TED.
1 Install the seat cushion TED.
2 Connect the seat cushion TED electrical connector.
3 Install the duct and zip-tie the duct to the TED.
2. Install the TED to the mounting bezel, and install the screw. 3. Install the seat cushion foam pad.
4. Install the seat cushion trim cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9643
5. Attach the J-clips (six shown). 6. Install the front height power seat motor. 7. Install the seat fan
motor. 8. Install the seat side shield. 9. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat
Backrest Thermo-Electric Device > Page 9644
Seat Heater: Service and Repair Seat Fan Motor
SEAT FAN MOTOR
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Remove the seat fan motor.
1 Cut the zip-tie and separate the duct from the seat fan motor.
2 Cut the zip-tie and separate the duct from the seat fan motor.
3 Disconnect the seat fan motor wire harness electrical connector.
4 Remove the screws.
5 Remove the fan motor.
Installation
1. Install the seat fan motor.
1. Install the seat fan motor. 2
Install the screws.
3 Connect the seat fan motor wire harness electrical connector.
4 Install the duct to seat fan motor and install zip-tie.
5 Install the duct to seat fan motor and install zip-tie.
2. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative
Seat Heater Control Module: Customer Interest A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative > Page 9653
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9658
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
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9659
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9660
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9661
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9662
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9663
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9664
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9665
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9666
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9667
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page
9668
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and
P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 05-14-4 > Jul > 05 > Engine Controls - MIL ON/DTC's P2106 and
P2135 Set > Page 9674
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-19-14 > Oct > 06 > Customer Interest
for Seat Heater Control Module: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative
Seat Heater Control Module: Customer Interest A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-19-14 > Oct > 06 > Customer Interest
for Seat Heater Control Module: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters Inoperative > Page 9684
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
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Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-19-14 > Oct > 06 > Customer Interest
for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-19-14 > Oct > 06 > Customer Interest
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters
Inoperative
Seat Heater Control Module: All Technical Service Bulletins A/C - Front Seat Heaters Inoperative
TSB 07-16-8
08/20/07
CLIMATE CONTROL SEAT HEAT FUNCTION INOPERATIVE - VEHICLES BUILT PRIOR TO
3/24/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 06-6-8 to update the Service Procedure.
ISSUE Some 2005 Expedition/Navigator vehicles built before 3/24/2005 and equipped with climate
control seats may exhibit inoperative heating on one or both seats. There are no diagnostic trouble
codes (DTCs) associated with this issue and the cooling function will operate normally.
ACTION It may be necessary to replace the dual climate control seat module (DCCSM), or re-seat
the connectors. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THE FOLLOWING STEPS MUST BE PERFORMED IN ORDER TO AID IN DIAGNOSIS.
1. Turn the ignition switch to key on engine off (KOEO) position.
2. Run self test on DCCSM.
a. If DTCs are present do not continue with this TSB, follow normal Workshop Manual diagnostics
for the DTCs.
b. If no DTCs are present proceed to Step 3.
3. Start engine.
4. Activate driver and passenger seat heat mode. Set for high heat (three (3) LEDs should be on).
Let the system remain activated for at least 3 minutes.
NOTE
THE HEATED SEATS WILL TURN OFF AFTER FIFTEEN (15) MINUTES.
5. Monitor PIDs (9956 driver cushion, 9957 driver seat back, 9121 passenger cushion, and 9122
passenger seat back) to verify whether or not the seat(s) temperature increases. Also monitor PIDs
(9955 driver blower RPM and 9120 passenger blower RPM), to verify that the seat fan RPMs are
greater then zero.
a. If the three (3) LEDs remain ON, the fan remains ON, and there is no heat in one or both seats,
remove Fuse 2.118 and wait at least 2 minutes. This will reset the DCCSM. Reinstall the fuse and
recheck operation of the heated seat. If the concern is resolved by resetting, replace the DCCSM.
Refer to Section 501-10 of the Workshop Manual. If concern is not resolved proceed to Step 5b.
b. Check both connectors at the DCCSM for loose or improperly seated connection. Disconnect the
connectors at the module, verify there are no pin push outs or terminal concerns, then reconnect.
Recheck operation of the heated seat. If concern is resolved, return the vehicle to the customer. If
not, proceed with normal Workshop Manual, Section 501-10 diagnostics.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 07-16-8 > Aug > 07 > A/C - Front Seat Heaters
Inoperative > Page 9705
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071608A 2005 Expedition/Navigator 0.8 Hr.
Replace The Dual Climate Control Seat Module (DCCSM) (Do Not Use With 14056D, 12650D,
19700D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9710
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9711
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9712
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9713
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9714
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9715
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9716
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9717
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9718
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9719
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled
Seats DTC B272C or B272D > Page 9720
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine
Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2106 and P2135
Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-14-4 > Jul > 05 > Engine
Controls - MIL ON/DTC's P2106 and P2135 Set > Page 9728
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05
> Engine Controls - MIL ON/DTC's P2106 and P2135 Set
Throttle Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2106
and P2135 Set
TSB 05-14-4
07/25/05
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND
PRIOR
FORD: 2003-2005 Thunderbird 2005 Crown Victoria, Mustang 2004-2005 Explorer, F-150 2005
E-Series, Expedition, F-Super Duty
LINCOLN: 2003-2005 LS 2005 Town Car, Navigator
MERCURY: 2005 Grand Marquis 2004-2005 Mountaineer
This article supersedes TSB 05-09-15 to update the Issue and Dealer Coding.
ISSUE Some vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106
and P2135 diagnostic trouble codes (DTCs).
ACTION Replace the throttle position sensor (TPS) following the instruction sheet included in the
TPS service kit. Reprogram the powertrain control module (PCM) to the latest calibration using
WDS release B36.11 and higher, or B37.2 and higher. This new calibration is not included in the
B37 CD. Calibration files are also available at the website.
CAUTION
FAILURE TO FOLLOW THE TPS REMOVAL AND INSTALLATION PROCEDURE WILL RESULT
IN DAMAGE TO THE TPS SCREWS.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-14-4 > Jul > 05
> Engine Controls - MIL ON/DTC's P2106 and P2135 Set > Page 9734
Labor Operations Claiming Chart
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E928 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Technical Service Bulletins > Page 9735
View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Technical Service Bulletins > Page 9736
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
For information on the electronic throttle body position sensor, refer to the description of the ETB in
Torque Based Electronic Throttle Control (ETC).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 9739
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
The TP sensor monitors the throttle position and provides an electrical signal to the PCM. It is
monitored by the OBD system for component integrity, system functionality, and faults that can
cause emissions levels to exceed the standards set by government regulations. For additional
information on the TP sensor, refer to PCM Inputs.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Description and Operation > Page 9740
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner
assembly. 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Installation
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4.
Connect the battery ground cable.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
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View 151-5 (Engine, Rear)
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Component
Information > Page 9742
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9751
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9752
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9753
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9754
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9755
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9756
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9757
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist
Vacuum Brake Booster: All Technical Service Bulletins Brakes - Unintended Brake Assist
TSB 05-26-21
12/31/05
UNINTENDED BRAKE ASSIST
FORD: 2003-2006 Expedition
LINCOLN: 2003-2006 Navigator
ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal
effort, due to the mechanical or electronic brake assist being activated.
ACTION Review the brake assist characteristics and follow the Service Procedure if required.
Brake Assist Characteristics: The booster gain will be increased during panic braking, which
increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and
the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be
present). The pedal efforts will drop dramatically since the booster is providing maximum boost,
which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels
excessively, but the system is generating maximum brake pressure when this occurs; again, this is
normal.
When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight
click. This is the brake assist feature engaging inside the booster. The system will remain active as
long as the brake pedal is depressed.
NOTE
MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH
RIDE STABILITY CONTROL.
Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides
the brake assist feature by activating an electronic solenoid inside the booster. The active booster
will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be
present.
SERVICE PROCEDURE
To service, first advise the customer that the feature is there to help assist during panic braking.
If the customer did not experience a panic braking situation, then the brake assist may have been
unintended, on a mechanical brake assist system. Check for conditions that would lower the brake
pedal height and activate the brake assist.
1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer
to the Workshop Manual, Section 206-00 General Procedures.
2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the
mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing.
3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as
necessary.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 30
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9776
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9777
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9778
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9779
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9780
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9781
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9782
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9783
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9784
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9785
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-26-21 > Dec > 05 > Customer Interest for Seat Heater
Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 9786
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Vacuum Brake Booster: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Vacuum Brake Booster: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D > Page 9792
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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DTC B272C or B272D > Page 9793
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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DTC B272C or B272D > Page 9794
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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DTC B272C or B272D > Page 9795
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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DTC B272C or B272D > Page 9796
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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DTC B272C or B272D > Page 9797
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9798
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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DTC B272C or B272D > Page 9799
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9800
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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DTC B272C or B272D > Page 9801
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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DTC B272C or B272D > Page 9802
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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B272D > Page 9811
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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B272D > Page 9812
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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B272D > Page 9813
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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B272D > Page 9814
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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B272D > Page 9816
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9817
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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B272D > Page 9818
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service
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B272D > Page 9819
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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B272D > Page 9820
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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B272D > Page 9821
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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DTC B272C or B272D > Page 9827
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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DTC B272C or B272D > Page 9828
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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DTC B272C or B272D > Page 9829
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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DTC B272C or B272D > Page 9830
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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DTC B272C or B272D > Page 9831
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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DTC B272C or B272D > Page 9832
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9833
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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DTC B272C or B272D > Page 9834
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9835
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D > Page 9836
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D > Page 9837
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service
Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9846
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service
Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9847
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service
Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9848
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service
Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9849
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9850
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9851
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9852
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or
B272D > Page 9853
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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B272D > Page 9854
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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B272D > Page 9855
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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B272D > Page 9856
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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DTC B272C or B272D > Page 9862
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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DTC B272C or B272D > Page 9863
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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DTC B272C or B272D > Page 9864
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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DTC B272C or B272D > Page 9865
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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DTC B272C or B272D > Page 9866
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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DTC B272C or B272D > Page 9867
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9868
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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DTC B272C or B272D > Page 9869
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service
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DTC B272C or B272D > Page 9870
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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DTC B272C or B272D > Page 9871
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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DTC B272C or B272D > Page 9872
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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DTC B272C or B272D > Page 9881
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats
DTC B272C or B272D > Page 9882
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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DTC B272C or B272D > Page 9883
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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DTC B272C or B272D > Page 9884
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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DTC B272C or B272D > Page 9885
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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DTC B272C or B272D > Page 9886
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9887
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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DTC B272C or B272D > Page 9888
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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DTC B272C or B272D > Page 9889
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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DTC B272C or B272D > Page 9890
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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DTC B272C or B272D > Page 9891
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Controlled Seats DTC B272C or B272D > Page 9898
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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Controlled Seats DTC B272C or B272D > Page 9899
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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Controlled Seats DTC B272C or B272D > Page 9900
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9903
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9904
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9905
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9906
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D > Page 9907
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move
Seat Track: Customer Interest Interior - Driver's Power Seat Will Not Move
TSB 05-18-14
09/22/05
DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 05-9-4 to update the part information and Service Procedure.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 12/06/2004 with memory seats
may exhibit the driver's power seat binding in the full rearward position and becoming inoperative in
forward and reverse. This may be due to the horizontal seat motor and memory seat position
sensor (potentiometer) on vehicles built before 10/16/2003, or due to the potentiometer (only) on
vehicles built between 10/16/2003 and 12/05/2004.
ACTION If the vehicle was built before 10/16/2003, inspect the horizontal motor bracket under the
seat. If the bracket has bends on either side of the seat motor, install a horizontal seat motor kit. If
the vehicle already has a straight bracket, or if the vehicle was built between 10/16/2003 and
12/05/2004, install a seat potentiometer kit only. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
WHEN INSTALLING A MOTOR KIT, THE SEAT TRACK FRONT COVER MUST ALSO BE
REPLACED. THE ORIGINAL SEAT TRACK FRONT COVER WILL NOT FIT ON THE NEWER
MOTOR ASSEMBLY BEING INSTALLED.
NOTE
FOR 2003 NAVIGATOR VEHICLES EQUIPPED WITH A BLACK INTERIOR, ORDER THE DOVE
GRAY SEAT TRACK FRONT COVER AND PAINT TO MATCH (BLACK INK).
REMOVAL - SEAT MOTOR ASSEMBLY OR POTENTIOMETER
1. Position the driver seat all the way up.
2. Remove the seat track front cover.
3. Check vehicle build date.
a. If built between 10/16/2003 and 12/05/2004, only a potentiometer kit will need to be installed.
Proceed to Step 4.
b. If built before 10/16/2003, inspect the horizontal seat motor bracket (cross bar) to determine if a
motor kit is needed, or only a potentiometer kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9916
(1) If the horizontal seat motor bracket has bends (Figure 1) a motor kit will need to be installed.
Proceed to Step 4.
(2) If the horizontal seat motor bracket is straight (Figure 2) only a potentiometer kit will need to be
installed. Proceed to Step 4.
4. Depower the supplemental restraint system (SRS). For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
5. Remove the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
6. Loosen the four (4) bolts under the seat track (Figure 3).
7. Disconnect the driver seat module (DSM) 24-pin electrical connector.
CAUTION
DO NOT APPLY POWER TO THE DSM IN THE FOLLOWING STEPS, OR DAMAGE WILL
OCCUR.
8. Using a remote power supply, position the seat track off the rear stop to full forward position
using the following steps:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9917
a. Apply battery voltage to the DSM wiring harness connector at location 1 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 2 (Figure 4).
9. Using the remote power supply again, position the seat track between mid travel and 2" (50 mm)
from the rear stop using the following steps.
a. Apply battery voltage to the DSM wiring harness connector at location 2 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 1 (Figure 4).
10. Disconnect the remote power supply.
11. Tighten the four (4) bolts under the seat track (Figure 5).
12. Reconnect the DSM electrical connector.
13. Disconnect the horizontal seat motor and seat position sensor electrical connectors.
14. Separate the horizontal seat motor assembly from the seat track studs using the following
steps:
a. Cut the two (2) horizontal motor drive cable tie straps at the inboard and outboard seat tracks.
b. Remove the two (2) nuts.
c. Using a suitable tool, pry up on the side of the horizontal motor bracket near the mounting stud
and separate the bracket from the stud.
d. Separate the horizontal motor bracket from the stud on the other side.
15. Lift up on the horizontal motor and bracket assembly, remove the drive cable from each seat
track, and remove the horizontal motor and bracket assembly. If installing a motor kit, proceed to
Step 2 of "INSTALLATION". If installing a potentiometer kit, proceed to Step 16.
16. Make note of the seat position sensor alignment to the motor for installation, then remove the
horizontal motor inboard cable and seat position sensor. To remove the seat position sensor from
the motor, pull straight out to disengage the locking tab. Proceed to Step 1 of "INSTALLATION".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9918
INSTALLATION
NOTE
ONE END OF THE INBOARD DRIVE CABLE WILL HAVE A LONGER SQUARE DRIVE THAN
THE OTHER END. THIS IS DUE TO THE LONGER SQUARE DRIVE HAVING TO PASS
THROUGH THE SEAT POSITION SENSOR AND MOTOR.
CAUTION
WHEN INSTALLING A NEW SEAT POSITION SENSOR, DO NOT BEND THE OUTBOARD
DRIVE CABLE, AS IT WILL HAVE TO BE REUSED. BENDING THE OUTBOARD DRIVE CABLE
CAN CAUSE NOISE ISSUES.
1. Install the seat position sensor using the following steps:
a. Align the seat position sensor to the horizontal motor as noted during removal and push in on the
sensor to install.
b. Install the inboard cable with the longer square drive end going into the sensor and motor. Turn
the cable and push in to engage to motor.
2. Verify the cables are engaged into the motor by confirming there is resistance when turning the
cable.
3. Feed the inboard and outboard drive cables into the seat tracks. By rotating the horizontal motor
and bracket assembly, the cables can be engaged into the inboard and outboard seat tracks
(Figure 6).
4. Align the horizontal motor bracket to the seat tracks and slide down on the studs.
5. Install the nuts (Figure 7).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9919
6. Connect the motor and seat position sensor electrical connectors (Figure 8).
CAUTION
DOUBLE CHECK THAT ALL CONNECTORS TO DSM, MOTOR, AND POTENTIOMETER ARE
PROPERLY CONNECTED BEFORE ATTACHING MAIN BODY HARNESS. IF THE POWER
SEAT IS OPERATED WHILE THE POTENTIOMETER IS DISCONNECTED, LOSS OF SOFT
STOP FUNCTION IS LIKELY AND WILL RESULT IN THE NEED TO REPLACE THE DSM.
SYMPTOMS OF A DISCONNECTED POTENTIOMETER IS
FORWARD/REARWARD SEAT MOVEMENT FOR ONLY ONE (1) SECOND BEFORE AN
AUTOMATIC STOP.
7. Using a heat gun, shrink tube the inboard and outboard cable ends to the seat track and install a
tie strap at each seat track.
8. Install the seat track front cover.
9. Install the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
10. Repower the supplemental restraint system. For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
11. To set the soft stop position, function the seat forward to at least mid-travel and then rearward
all the way to the rearmost position. Allow the seat to hit the rear stops and continue holding the
switch until the seat module clicks off (approximately 1 second after hitting the rear stops). This will
set the soft stop position.
12. Verify soft stop function is working properly with the following steps:
a. Access vehicle message center and check that EZ-Exit/Entry is "ON".
b. Move seat forward approximately 1" (25 mm) from full rear.
c. Remove key from ignition.
d. Observe seat behavior. Seat should move backwards approximately 1/2" to 3/4" (12 to 19 mm)
and stop.
e. Activate seat switch rearward, seat should still have 1/4" to 1/2" (6 to 12 mm) of travel to full rear.
f. If no movement observed in Step d, move seat slightly further forward and repeat Steps c
through e. If there is still no movement observed in Step d, replace the DSM per procedures in
Workshop Manual Section 419-10.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page 9920
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051814A 2003-2005 Expedition, 1.2 Hrs.
2004-2005 Navigator: Replace Horizontal Seat Motor Kit Or Potentiometer, Includes Time To
Install Seat Track Front Cover (Do Not Use With 14718A, 14547A)
051814B 2003 Navigator: Replace 1.3 Hrs.
Horizontal Seat Motor Kit Or Potentiometer Includes Time To Paint And Install Seat Track Front
Cover (Do Not Use With 14718A, 14547A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14547 41
OASIS CODES: 101000
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move
Seat Track: All Technical Service Bulletins Interior - Driver's Power Seat Will Not Move
TSB 05-18-14
09/22/05
DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
This article supersedes TSB 05-9-4 to update the part information and Service Procedure.
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 12/06/2004 with memory seats
may exhibit the driver's power seat binding in the full rearward position and becoming inoperative in
forward and reverse. This may be due to the horizontal seat motor and memory seat position
sensor (potentiometer) on vehicles built before 10/16/2003, or due to the potentiometer (only) on
vehicles built between 10/16/2003 and 12/05/2004.
ACTION If the vehicle was built before 10/16/2003, inspect the horizontal motor bracket under the
seat. If the bracket has bends on either side of the seat motor, install a horizontal seat motor kit. If
the vehicle already has a straight bracket, or if the vehicle was built between 10/16/2003 and
12/05/2004, install a seat potentiometer kit only. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
WHEN INSTALLING A MOTOR KIT, THE SEAT TRACK FRONT COVER MUST ALSO BE
REPLACED. THE ORIGINAL SEAT TRACK FRONT COVER WILL NOT FIT ON THE NEWER
MOTOR ASSEMBLY BEING INSTALLED.
NOTE
FOR 2003 NAVIGATOR VEHICLES EQUIPPED WITH A BLACK INTERIOR, ORDER THE DOVE
GRAY SEAT TRACK FRONT COVER AND PAINT TO MATCH (BLACK INK).
REMOVAL - SEAT MOTOR ASSEMBLY OR POTENTIOMETER
1. Position the driver seat all the way up.
2. Remove the seat track front cover.
3. Check vehicle build date.
a. If built between 10/16/2003 and 12/05/2004, only a potentiometer kit will need to be installed.
Proceed to Step 4.
b. If built before 10/16/2003, inspect the horizontal seat motor bracket (cross bar) to determine if a
motor kit is needed, or only a potentiometer kit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9926
(1) If the horizontal seat motor bracket has bends (Figure 1) a motor kit will need to be installed.
Proceed to Step 4.
(2) If the horizontal seat motor bracket is straight (Figure 2) only a potentiometer kit will need to be
installed. Proceed to Step 4.
4. Depower the supplemental restraint system (SRS). For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
5. Remove the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
6. Loosen the four (4) bolts under the seat track (Figure 3).
7. Disconnect the driver seat module (DSM) 24-pin electrical connector.
CAUTION
DO NOT APPLY POWER TO THE DSM IN THE FOLLOWING STEPS, OR DAMAGE WILL
OCCUR.
8. Using a remote power supply, position the seat track off the rear stop to full forward position
using the following steps:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9927
a. Apply battery voltage to the DSM wiring harness connector at location 1 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 2 (Figure 4).
9. Using the remote power supply again, position the seat track between mid travel and 2" (50 mm)
from the rear stop using the following steps.
a. Apply battery voltage to the DSM wiring harness connector at location 2 (Figure 4).
b. Briefly apply battery ground to the DSM wiring harness connector at location 1 (Figure 4).
10. Disconnect the remote power supply.
11. Tighten the four (4) bolts under the seat track (Figure 5).
12. Reconnect the DSM electrical connector.
13. Disconnect the horizontal seat motor and seat position sensor electrical connectors.
14. Separate the horizontal seat motor assembly from the seat track studs using the following
steps:
a. Cut the two (2) horizontal motor drive cable tie straps at the inboard and outboard seat tracks.
b. Remove the two (2) nuts.
c. Using a suitable tool, pry up on the side of the horizontal motor bracket near the mounting stud
and separate the bracket from the stud.
d. Separate the horizontal motor bracket from the stud on the other side.
15. Lift up on the horizontal motor and bracket assembly, remove the drive cable from each seat
track, and remove the horizontal motor and bracket assembly. If installing a motor kit, proceed to
Step 2 of "INSTALLATION". If installing a potentiometer kit, proceed to Step 16.
16. Make note of the seat position sensor alignment to the motor for installation, then remove the
horizontal motor inboard cable and seat position sensor. To remove the seat position sensor from
the motor, pull straight out to disengage the locking tab. Proceed to Step 1 of "INSTALLATION".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9928
INSTALLATION
NOTE
ONE END OF THE INBOARD DRIVE CABLE WILL HAVE A LONGER SQUARE DRIVE THAN
THE OTHER END. THIS IS DUE TO THE LONGER SQUARE DRIVE HAVING TO PASS
THROUGH THE SEAT POSITION SENSOR AND MOTOR.
CAUTION
WHEN INSTALLING A NEW SEAT POSITION SENSOR, DO NOT BEND THE OUTBOARD
DRIVE CABLE, AS IT WILL HAVE TO BE REUSED. BENDING THE OUTBOARD DRIVE CABLE
CAN CAUSE NOISE ISSUES.
1. Install the seat position sensor using the following steps:
a. Align the seat position sensor to the horizontal motor as noted during removal and push in on the
sensor to install.
b. Install the inboard cable with the longer square drive end going into the sensor and motor. Turn
the cable and push in to engage to motor.
2. Verify the cables are engaged into the motor by confirming there is resistance when turning the
cable.
3. Feed the inboard and outboard drive cables into the seat tracks. By rotating the horizontal motor
and bracket assembly, the cables can be engaged into the inboard and outboard seat tracks
(Figure 6).
4. Align the horizontal motor bracket to the seat tracks and slide down on the studs.
5. Install the nuts (Figure 7).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9929
6. Connect the motor and seat position sensor electrical connectors (Figure 8).
CAUTION
DOUBLE CHECK THAT ALL CONNECTORS TO DSM, MOTOR, AND POTENTIOMETER ARE
PROPERLY CONNECTED BEFORE ATTACHING MAIN BODY HARNESS. IF THE POWER
SEAT IS OPERATED WHILE THE POTENTIOMETER IS DISCONNECTED, LOSS OF SOFT
STOP FUNCTION IS LIKELY AND WILL RESULT IN THE NEED TO REPLACE THE DSM.
SYMPTOMS OF A DISCONNECTED POTENTIOMETER IS
FORWARD/REARWARD SEAT MOVEMENT FOR ONLY ONE (1) SECOND BEFORE AN
AUTOMATIC STOP.
7. Using a heat gun, shrink tube the inboard and outboard cable ends to the seat track and install a
tie strap at each seat track.
8. Install the seat track front cover.
9. Install the driver seat. For additional information, refer to Workshop Manual Section 501-10
(Front Seat - 40 Percent).
10. Repower the supplemental restraint system. For additional information, refer to Workshop
Manual Section 501-20B (SRS Depowering and Repowering).
11. To set the soft stop position, function the seat forward to at least mid-travel and then rearward
all the way to the rearmost position. Allow the seat to hit the rear stops and continue holding the
switch until the seat module clicks off (approximately 1 second after hitting the rear stops). This will
set the soft stop position.
12. Verify soft stop function is working properly with the following steps:
a. Access vehicle message center and check that EZ-Exit/Entry is "ON".
b. Move seat forward approximately 1" (25 mm) from full rear.
c. Remove key from ignition.
d. Observe seat behavior. Seat should move backwards approximately 1/2" to 3/4" (12 to 19 mm)
and stop.
e. Activate seat switch rearward, seat should still have 1/4" to 1/2" (6 to 12 mm) of travel to full rear.
f. If no movement observed in Step d, move seat slightly further forward and repeat Steps c
through e. If there is still no movement observed in Step d, replace the DSM per procedures in
Workshop Manual Section 419-10.
Parts Block
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-18-14 > Sep > 05 > Interior - Driver's Power Seat Will Not Move > Page
9930
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051814A 2003-2005 Expedition, 1.2 Hrs.
2004-2005 Navigator: Replace Horizontal Seat Motor Kit Or Potentiometer, Includes Time To
Install Seat Track Front Cover (Do Not Use With 14718A, 14547A)
051814B 2003 Navigator: Replace 1.3 Hrs.
Horizontal Seat Motor Kit Or Potentiometer Includes Time To Paint And Install Seat Track Front
Cover (Do Not Use With 14718A, 14547A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14547 41
OASIS CODES: 101000
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power
Seat Track: Service and Repair Seat Track - Power
SEAT TRACK - POWER
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
Inboard and outboard seat tracks 1. Remove the 40 percent seat and depower the SRS.
2. Remove the spring.
Driver seat
3. CAUTION: Make sure to remove all metal chips from seat position sensor and surrounding areas
after drilling out rivet.
Remove the seat position sensor. 1
Disconnect the seat position sensor electrical connector.
2 Drill out rivet.
3 Remove the seat position sensor.
Inboard seat track
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9933
4. Pull to remove the inboard forward/reverse motor drive cable from inboard seat track. 5.
Disconnect the safety belt buckle pretensioner and usage detection electrical connectors.
6. Remove the safety belt buckle pretensioner.
1 Remove the nut.
2 Remove the safety belt buckle pretensioner.
7. Remove the four inboard seat track nuts.
8. Remove the rear inboard seat track and bracket.
1 Remove the bolt.
2 Remove the seat track and bracket. Remove the two remaining nuts (not shown) that hold the bracket to seat track.
Outboard seat track
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9934
9. Pull to remove the outboard forward/reverse motor drive cable from outboard seat track
Vehicles with 6-way power seat
10. Disconnect the 6-way power seat switch electrical connector.
11. Remove recliner handle cover.
12. Remove the recliner handle screw and remove handle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9935
13. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even
pressure on both sides of the knob to remove.
Remove the lumbar knob.
14. Remove the screw from side shield under the lumbar knob.
15. CAUTION: Use care not to scratch the side shield when removing the power seat knob.
Pry the power seat knob off.
16. Access and remove the front side shield screw.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9936
17. Pull to release the retainer clip on the rear of side shield. 18. Remove the side shield from the
seat.
Vehicles with 8-way power seat
19. Pry to remove the two power seat knobs and remove the knobs.
20. Access and remove the front side shield screw.
21. Pull out from the bottom and rear side of side shield to release the three retainer clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9937
22. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors and
remove the side shield.
Outboard seat track
23. Remove the outboard seat track.
1 Remove the nuts.
2 Remove the seat track.
Installation
Outboard seat track 1. Install the outboard seat track.
1 Install the seat track.
2 Install the nuts.
Vehicles with 8-way power seat
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9938
2. Install side shield and connect the 8-way power seat and power lumbar switch electrical
connectors.
3. Push to install the three side shield retainers onto the seat frame.
4. Access and install the front side shield screw.
5. Install the two power seat knobs.
Vehicles with 6-way power seat
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9939
6. Install the 6-way power seat switch on the side shield and install the two screws. 7. Install the
side shield on the seat.
8. Push to install the rear side shield retainer onto the seat frame.
9. Access and install the front side shield screw.
10. Install the 6-way power seat knob.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9940
11. Install the screw on the side shield.
12. Align and install the lumbar knob.
13. Install recliner handle and install the screw.
14. Install the recliner handle cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9941
15. Connect the 6-way power seat switch electrical connector.
Outboard seat track
16. Install the outboard forward/reverse motor drive cable to outboard seat track.
Inboard seat track 17. Install the bracket to the seat track and install the two nuts.
18. Install the rear inboard seat track and bracket.
1 Install the seat track and bracket.
2 Install the bolt.
19. Install the four inboard seat track nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9942
20. Install the safety belt buckle pretensioner.
1 Install the safety belt buckle pretensioner.
2 Install the nut.
21. Connect the safety belt buckle pretensioner and usage detection electrical connectors.
22. Install the inboard forward/reverse motor drive cable to seat track.
Driver seat
23. CAUTION: Make sure to remove all metal chips from seat position sensor and surrounding
areas.
Install the seat position sensor. 1
Install the seat position sensor.
2 Install the rivet.
3 Connect the seat position sensor electrical connector.
Inboard and outboard seat tracks
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9943
24. Install the spring. 25. Install the 40 percent seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9944
Seat Track: Service and Repair Seat Track - Manual
SEAT TRACK - MANUAL
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. NOTE: 60 percent seat shown, the 40 percent seat similar.
Remove the affected seat and depower the SRS.
2. Remove recliner handle cover.
3. Remove the recliner handle screw and remove handle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9945
4. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure
on both sides of the knob to remove.
Remove the lumbar knob.
5. Remove the screw from the side shield under lumbar knob.
6. Remove the screw from the front of the side shield.
7. Remove the screw from the back of the side shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9946
8. Remove the manual seat track riser and adjust handle.
1 Remove the four seat riser nuts (two shown).
2 Remove the seat riser.
3 Remove the four adjust handle bolts (two shown).
4 Remove the manual seat track handle.
9. Remove the two front manual seat track-to-cushion frame bolts (one shown).
10. Remove the two rear manual seat track-to-cushion frame bolts (one shown). 11. Remove the
manual seat track.
Installation
1. Install the manual seat track.
2. Install the two rear manual seat track-to-cushion frame bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9947
3. Install the two front manual seat track-to-cushion frame bolts (one shown).
4. Install the seat track riser and adjust handle.
1 Install the manual seat track adjust handle.
2 Install the four seat track adjust handle bolts (two shown).
3 Install the manual seat track risers.
4 Install the four seat riser to seat track nuts (two shown).
5. Install the screws on the back of the side shield.
6. Install the screw on the front of side shield.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat
Track - Power > Page 9948
7. Install the screw on side shield.
8. Align and install the lumbar knob.
9. Install recliner handle and install the screw.
10. Install the recliner handle cover. 11. Install the affected seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front > Page 9954
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front > Page 9957
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 9958
Vacuum/Pressure Pump Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 9959
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 9960
Vacuum/Pressure Pump Switch: Service and Repair
LUMBAR CONTROL SWITCH
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Access and remove the front side shield screw.
3. Pull out from the bottom and rear side of side shield to release the three retainer clips.
4. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 9961
5. Pinch retainer in and push from the rear of power lumbar switch to remove the switch from the
side shield.
Installation
1. Install the power lumbar switch into the side shield.
2. Connect the 8-way power seat and power lumbar switch electrical connectors.
3. Push to install the three side shield retainers onto the seat frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 9962
4. Access and install the front side shield screw. 5. Install the 40 percent seat and repower the
SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor >
Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 9970
Pedal Positioning Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - Without Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 9973
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 9974
Pedal Positioning Switch: Testing and Inspection Adjustable Pedal Switch - With Memory
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Testing and Inspection > Adjustable Pedal Switch - Without Memory > Page 9975
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Driver Side
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Driver Side > Page 9980
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side
Power Door Lock Switch: Diagrams Driver Side
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Driver Side > Page 9983
Power Door Lock Switch: Diagrams Passenger Side
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9984
Power Door Lock Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9985
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9989
Power Mirror Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9990
Power Mirror Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9991
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9992
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
Removal and Installation
All vehicles 1. Remove the driver front door trim panel.
Navigator
2. Depress the locking tabs and remove the exterior mirror control switch.
Expedition
3. Remove the exterior mirror control switch.
1 Depress the locking tabs.
2 Remove the exterior mirror control switch.
All vehicles 4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 9997
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 9998
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 9999
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10000
Power Seat Motor Position Sensor: Locations
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10001
View 151-35 (Chassis, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10002
View 151-36 (Chassis, Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10003
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10004
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10005
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10008
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10009
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10010
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10011
Power Seat Motor Position Sensor: Diagrams Height Sensor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position
Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10012
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 10017
Power Seat Switch: Locations Power Seat Switch
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 10018
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch
Power Seat Switch: Diagrams Power Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch > Page 10021
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch > Page 10022
Power Seat Switch: Diagrams Third Row Folding Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch
Power Seat Switch: Testing and Inspection Power Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10025
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10026
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10027
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10028
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10029
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10030
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10031
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10032
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10033
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10034
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10035
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10036
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10037
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10038
Power Seat Switch: Testing and Inspection Third Row Folding Seat Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10039
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10040
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch > Page 10041
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way
Power Seat Switch: Service and Repair Seat Control Switch - 8-Way
SEAT CONTROL SWITCH - 8-WAY
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver side shown, passenger side similar.
1. Remove the affected seat and depower the SRS.
2. Pry to remove the two power seat knobs and remove the knobs.
3. Access and remove the front side shield screw.
4. Pull out from the bottom and rear side of side shield to release the three retainer clips.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10044
5. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors.
6. Remove the three screws and remove the power seat switch.
Installation
1. Install the power seat switch and install the three screws.
2. Connect the 8-way power seat and power lumbar switch electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10045
3. Push to install the three side shield retainers onto the seat frame.
4. Access and install the front side shield screw.
5. Install the two power seat knobs. 6. Install the affected seat and repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10046
Power Seat Switch: Service and Repair Seat Control Switch - 6-Way
SEAT CONTROL SWITCH - 6-WAY
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver seat is shown, passenger is similar.
1. Remove the affected seat and depower the SRS.
2. Disconnect the 6-way power seat switch electrical connector.
3. Remove the recliner handle screw cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10047
4. Remove the recliner handle screw and the recliner handle.
5. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure
on both sides of the knob to remove.
Pull out to remove the lumbar knob.
6. Remove the screw from the side shield under the lumbar knob.
7. CAUTION: Use care not to scratch the side shield when removing the power seat knob.
Pry the power seat knob off.
8. Access and remove the front side shield screw.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10048
9. Pull to release the center retainer on side shield.
10. Pull to release the retainer clip on the rear of side shield. 11. Remove the side shield from the
seat.
12. Remove the two screws and remove the 6-way power seat switch from the side shield.
Installation
1. Install the 6-way power seat switch on the side shield and install the two screws.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10049
2. Push to install the rear side shield retainer on seat frame.
3. Push to install the middle side shield retainer on the seat.
4. Access and install the front side shield screw.
5. Install the 6-way power seat knob.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10050
6. Install the screw on the side shield under the lumbar knob.
7. Align and install the lumbar knob.
8. Install the recliner handle and install the screw.
9. Install the recliner handle cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10051
10. Connect the 6-way power seat switch electrical connector. 11. Install the affected seat and
repower the SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Seat Control Switch - 8-Way > Page 10052
Power Seat Switch: Service and Repair Seat Control Switch - Third Row
SEAT CONTROL SWITCH - THIRD ROW
Removal and Installation
1. Partially remove the RH quarter trim panel for access to the third row power seat switch(es). 2.
Remove the retainer nuts on the back side of the power seat switch housing.
3. Disconnect the power seat switch electrical connectors.
4. Release the four locking tabs (two shown) on the affected switch, and remove the switch. 5. To
install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard
Sensor > Component Information > Service and Repair
Power Trunk / Liftgate Hazard Sensor: Service and Repair
PINCH STRIP SWITCH
Removal and Installation
NOTE: Left side shown, right side similar.
1. Remove brake light.
- Remove the screws.
2. Disconnect the pinch strip electrical connector.
3. Remove the pinch strip.
1 Remove the pin-type retainers.
2 Remove the grommet and route the harness out of the vehicle.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 10059
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10068
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10069
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10070
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10071
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10072
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10073
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10074
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10075
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10076
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10077
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
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Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10084
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 >
Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10086
8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 >
Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10087
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate
Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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Controlled Seats DTC B272C or B272D > Page 10103
3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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Controlled Seats DTC B272C or B272D > Page 10104
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
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c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
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8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
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11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
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b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
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16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
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a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
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11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
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A/C - Climate Controlled Seats DTC B272C or B272D
Technical Service Bulletin # 06-13-6 Date: 060710
A/C - Climate Controlled Seats DTC B272C or B272D
TSB 06-13-6
07/10/06
DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE
FORD: 2005-2006 Expedition
LINCOLN: 2005-2006 Navigator
This article supersedes TSB 05-14-10 to update the Service Procedure.
ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit
concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs)
B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential
Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various
sources, making them difficult to diagnose.
ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC
B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
MT061306 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14C724 42
Disclaimer
Section 1
SECTION 1
1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General
Procedures; Supplemental Restraint System Depowering and Repowering.
2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a,
C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully
seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the
customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3.
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3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS
fails when activated in the heat mode.
a. If the time to failure is 5 seconds or less then, proceed to Section 2.
b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section
3.
c. If the time to failure is 40 seconds or greater, then, proceed to Section 4.
NOTE
THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4
THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE
PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED.
THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT
BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK.
Section 2
SECTION 2 (Seat Shuts Off In Less Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present
(B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present
after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system.
a. If there is an over-temp DTC present then go to Step 3.
b. If no over-temp DTC is present then go to Step 6.
3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature
conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than
the other TED?
a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go
to Step 4.
b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11.
c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If
blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair
as needed.
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4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger
cushion) Figure 1.)
a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate
control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is
shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM.
b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms?
(1) If no, then replace TED.
(2) If yes, go to Step 5.
5. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then go to Step 6.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to
Step 12.
b. If not then proceed to Step 7.
7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, then proceed to Step 8.
b. If no, then go to Step 9 in Section 3.
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8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion)
a. If plugged in, then proceed to Step 9.
b. If not plugged in, then correct and proceed to Step 12.
9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM).
(Figure 2)
a. If it is open, then proceed to Step 10.
b. If it is not open, then proceed to Step 11.
10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the
harnesses).
a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step
12.
b. If the wire harnesses are good, then proceed to Step 11.
11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms
(proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room
temperature)?
a. No, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. Yes, then replace the DCCSM and proceed to Step 12.
12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to
customer.
Section 3
SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds)
1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed
and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2.
2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is
present (B2729, B2730, B272A, B272B).
a. If there is an over-temp DTC present, then continue to Step 3.
b. If there is no over-temp DTC present, then continue to Step 5.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10122
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room
temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading
10° higher than the other TED?
a. If readings are hotter than room temperature, go to Step 4.
b. If TED temperatures between Back and Cushion are 100 different, go to Step 12.
c. If reading correctly then, proceed to Step 5.
4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector
(C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger
Cushion). (Figure 1)
a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver
Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on.
(1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground.
(2) If yes, fix the wiring, if no replace the DCCSM.
b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms?
(1) If yes, go to Step 5.
(2) If no, then replace TED. (Figure 2)
5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)?
a. If yes, go to Step 6.
b. If no, go to Step 7.
6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the
harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger
Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to
Pin 2.
a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by
checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector
C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM,
otherwise replace the harness. Verify system now functions and return vehicle to customer.
b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system
now functions and return vehicle to customer.
7. Cycle ignition and enter into high cool mode. Does failure still occur?
a. If no, proceed to Step 8.
b. If yes, proceed to Step 13.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10123
8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED
connector.
NOTE
DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE
a. If voltage is not getting to the suspect TED, proceed to Step 9.
b. If voltage is getting to the suspect TED, replace TED.
9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the
module. (Figure 3)
^ Driver Cushion - Pin 9
^ Driver Backrest - Pin 8
^ Passenger Cushion - Pin 11
^ Passenger Backrest - Pin 22
a. If no voltage is coming out of the module, then replace the module and continue to Step 13.
b. If the correct voltage is coming out of the module, then continue to Step 10.
10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from
the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found,
then continue to Step 11. (Figure 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10124
11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2
volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not
reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5)
12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms
(proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room
temperature)?
a. If no, then replace the TED that is outside the resistance range specified above, assuming the
TED is at room temperature, and proceed to Step 12.
b. If yes, then proceed to Step 13.
13. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1.
b. Time to failure is not different than before, then continue to Step 14.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10125
14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7)
a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10126
b. If there are no kinks or obstructions of the ducting then, continue to Step 16.
15. If CCS continues to be inoperable with a B272C/D code and:
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 16.
c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return
vehicle to customer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10127
16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been
obstructed or damaged or bunched in the cushion blocking air flow from the TED.
a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 17.
b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then
replace the TED and continue to Step 17.
17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3
in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer.
Section 4
SECTION 4 (Seat Shuts Off After More Than 40 Seconds)
1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected
seat when a heating cycle is initiated.
a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2.
b. If the TEDs both increase temperature, then proceed to Step 3.
2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED
that does not increase temperature from Step 1.
a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed
to Step 3.
b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED,
verify the fix and proceed to Step 6.
3. Check for any kinks or obstructions of the ducting from the fan to the TED.
a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible
otherwise replace the ducting and continue to Step 4.
b. If there are no kinks or obstructions of the ducting, then continue to Step 5.
4. If CCS continues to be inoperable with DTC B272C/D code and
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10128
a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1.
b. Time to failure is not different than before, then continue to Step 5.
c. If CCS is now operable, then repower the SRS and return vehicle to customer.
5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or
damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion
alignment is incorrect.
a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6.
b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6.
c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the
damaged cushion/scrim and continue to Step 6.
d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a
climate control seat, then replace the TED and continue to Step 6.
6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in
Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer.
Section 5
SECTION 5 (Spread Terminal Fix Procedure)
1. Position the front passenger seat fully rearward and up.
2. Pull out and remove the seat track front cover.
3. Disconnect Connector C3265B 24-pin gray. (Figure 3).
4. Remove the red secondary wedge inside the connector.
5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in
cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3).
NOTE
DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE
NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED
INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG
CAVITY.
6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the
terminal) and bend the spring into the proper position (Figure 10).
7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the
connector.
8. Reconnect C3265B to the dual climate control seat module.
9. Reinstall the seat track front cover.
10. Repower the SRS. Refer to WSM, Section 501-20B.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 >
A/C - Climate Controlled Seats DTC B272C or B272D > Page 10129
11. Verify the climate control seat function, and recheck DTCs.
12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in
Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return
vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 10133
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 10134
Seat Memory Switch: Testing and Inspection
SWITCH - MEMORY SET
Memory Set Switch
Remove the memory set switch.
Measure the resistance between the indicated terminals while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to
the calling pinpoint test.
NOTE: Refer to multimeter user's manual for testing diodes.
To check the memory set switch LED, connect the positive meter lead to terminal 7 and the
negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, install a new switch; otherwise, return to the
calling pinpoint test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10138
Sunroof / Moonroof Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10139
Sunroof / Moonroof Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10140
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 10145
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 10146
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 10149
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 10150
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front
View 151-26 (Driver Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front > Page 10155
View 151-27 (Passenger Seat)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front > Page 10158
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 10159
Vacuum/Pressure Pump Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 10160
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 10161
Vacuum/Pressure Pump Switch: Service and Repair
LUMBAR CONTROL SWITCH
Removal
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the 40 percent seat and depower the SRS.
2. Access and remove the front side shield screw.
3. Pull out from the bottom and rear side of side shield to release the three retainer clips.
4. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 10162
5. Pinch retainer in and push from the rear of power lumbar switch to remove the switch from the
side shield.
Installation
1. Install the power lumbar switch into the side shield.
2. Connect the 8-way power seat and power lumbar switch electrical connectors.
3. Push to install the three side shield retainers onto the seat frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch,
Seats > Component Information > Diagrams > Page 10163
4. Access and install the front side shield screw. 5. Install the 40 percent seat and repower the
SRS.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Remove the windshield wipers. 2. Remove the cowl grille seal.
3. Remove the pin-type retainer and left side cowl trim panel.
- Disconnect the windshield washer tube.
4. Remove the right side cowl trim panel.
1 Disconnect the windshield washer tube.
2 Remove the pin-type retainer.
5. If necessary, adjust the windshield wiper arms. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash
Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High
Pressure Car Wash
TSB 08-24-8
12/08/08
WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH
FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition
LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT
This article supersedes TSB 08-1-4 to update the Part List and Service procedure.
ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008
Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear
of roof opening panel during a high pressure car wash.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT
1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner
or equivalent.
5. Remove the adhesive tape covering from trough seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 10181
6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal
lines up against front flange of trough. (Figures 1-3)
7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough.
8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining
screws and torque to 9 lb-in. (1 N.m)
9. Remove protective covering.
10. Install roof opening panel following WSM, Section 501-17.
2005-2009 Expedition / Navigator
1. Remove roof opening panel glass only. Refer to WSM, Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. Install new trough and seal assembly.
5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2)
trough guide retaining screws and torque to 9 lb-in. (1 N.m)
6. Remove protective covering.
7. Install roof opening panel following WSM, Section 501-17.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 10182
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082408A 2005-2009 Expedition, 0.5 Hr.
Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A)
082408A 2005-2008 F-Super Duty, 0.6 Hr.
F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use
With 5028A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502C50 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 >
Body - Sunroof Water Leaks During High Pressure Car Wash
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks
During High Pressure Car Wash
TSB 08-24-8
12/08/08
WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH
FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition
LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT
This article supersedes TSB 08-1-4 to update the Part List and Service procedure.
ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008
Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear
of roof opening panel during a high pressure car wash.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT
1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner
or equivalent.
5. Remove the adhesive tape covering from trough seal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 >
Body - Sunroof Water Leaks During High Pressure Car Wash > Page 10188
6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal
lines up against front flange of trough. (Figures 1-3)
7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough.
8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining
screws and torque to 9 lb-in. (1 N.m)
9. Remove protective covering.
10. Install roof opening panel following WSM, Section 501-17.
2005-2009 Expedition / Navigator
1. Remove roof opening panel glass only. Refer to WSM, Section 501-17.
2. To avoid paint damage to the roof, apply protective covering on roof finish.
3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from
the trough guide assembly.
4. Install new trough and seal assembly.
5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2)
trough guide retaining screws and torque to 9 lb-in. (1 N.m)
6. Remove protective covering.
7. Install roof opening panel following WSM, Section 501-17.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 >
Body - Sunroof Water Leaks During High Pressure Car Wash > Page 10189
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082408A 2005-2009 Expedition, 0.5 Hr.
Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A)
082408A 2005-2008 F-Super Duty, 0.6 Hr.
F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use
With 5028A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502C50 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information >
Technical Service Bulletins > Page 10190
Sunroof / Moonroof Weatherstrip: Service and Repair
ROOF OPENING PANEL WEATHERSTRIP
Removal
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the
roof opening panel, including: whenever the roof opening panel has been removed from the roof
opening panel assembly, a new roof opening panel motor/module has been installed, or when a
new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor
Initialization. See: Roof and Associated Components/Sunroof / Moonroof/Service and Repair/Roof
Opening Panel Motor Initialization
1. Remove the roof opening panel. 2. Place roof opening panel, topside up, on a worktable. Take
care to support the glass assembly from below to prevent damaging the mounting tabs.
3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip.
Installation
1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the
passenger side. 2. Starting with the corners, push the weatherstrip into position. Continue pushing
the weatherstrip into position around the glass assembly until
complete. Use a plastic or rubber hammer if necessary.
3. Install the roof opening panel. 4. Adjust the roof panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch > Page 10196
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams >
Deactivator Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams >
Deactivator Switch > Page 10199
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch > Page 10202
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake
Deactivator Switch
BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH
The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control
deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the
brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens
and power is removed from the PCM.
On some applications the normally closed BPS, along with the normally open brake pedal position
(BPP) switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile
learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to
the PCM did not change states when they were expected to, a diagnostic trouble code P1572 can
be set by the PCM strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Page 10203
Brake Switch (Cruise Control): Service and Repair
SPEED CONTROL DEACTIVATOR SWITCH
Removal
1. NOTE: The speed control deactivator switch can only be adjusted once. If further adjusting is
necessary, install a new switch.
Remove the deactivator switch. 1
Disconnect the electrical connector.
2 Rotate the deactivator switch counterclockwise 45 degrees and remove it.
Installation
All vehicles
1. Release the plunger lock (if equipped).
- Turn the lock knob counterclockwise until the first click is felt.
2. Fully press the brake pedal.
3. Install the deactivator switch.
1 Position the deactivator switch in the bracket and rotate it clockwise 45 degrees.
2 Connect the electrical connector.
Vehicles equipped with a locking tab
4. NOTE: There should be an extra click heard when tugging on the brake pedal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Page 10204
Slowly release the brake pedal and tug it moderately once the pedal reaches the rest position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and
Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed
Control Switch - With Remote Audio/Climate Control
Cruise Control Switch: Service and Repair Speed Control Switch - With Remote Audio/Climate
Control
SPEED CONTROL SWITCH - WITH REMOTE AUDIO/CLIMATE CONTROL
Removal and Installation
All vehicles 1. Remove the driver side air bag module.
Expedition
2. Remove the speed control switch.
1 Disconnect the electrical connector.
2 Remove the screws.
Navigator
3. Remove the horn switch.
1 Disconnect the electrical connector.
2 Remove the bolts.
4. Remove the speed control switch.
1 Disconnect the wiring harness locators.
2 Remove the screws.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed
Control Switch - With Remote Audio/Climate Control > Page 10212
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed
Control Switch - With Remote Audio/Climate Control > Page 10213
Cruise Control Switch: Service and Repair Speed Control Switch - Without Remote Audio/Climate
Control
SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROL
Removal and Installation
1. Remove the driver side air bag module.
2. Remove the speed control actuator switch.
1 Release the four (A) speed control actuator switch clips and remove the (B) speed control
actuator switch.
2 Disconnect the speed control actuator switch electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch > Page 10219
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Deactivator Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Deactivator Switch > Page 10222
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 10225
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake
Deactivator Switch
BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH
The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control
deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the
brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens
and power is removed from the PCM.
On some applications the normally closed BPS, along with the normally open brake pedal position
(BPP) switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile
learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to
the PCM did not change states when they were expected to, a diagnostic trouble code P1572 can
be set by the PCM strategy.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Page 10226
Brake Switch (Cruise Control): Service and Repair
SPEED CONTROL DEACTIVATOR SWITCH
Removal
1. NOTE: The speed control deactivator switch can only be adjusted once. If further adjusting is
necessary, install a new switch.
Remove the deactivator switch. 1
Disconnect the electrical connector.
2 Rotate the deactivator switch counterclockwise 45 degrees and remove it.
Installation
All vehicles
1. Release the plunger lock (if equipped).
- Turn the lock knob counterclockwise until the first click is felt.
2. Fully press the brake pedal.
3. Install the deactivator switch.
1 Position the deactivator switch in the bracket and rotate it clockwise 45 degrees.
2 Connect the electrical connector.
Vehicles equipped with a locking tab
4. NOTE: There should be an extra click heard when tugging on the brake pedal.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Page 10227
Slowly release the brake pedal and tug it moderately once the pedal reaches the rest position.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Speed Control Switch - With Remote Audio/Climate Control
Cruise Control Switch: Service and Repair Speed Control Switch - With Remote Audio/Climate
Control
SPEED CONTROL SWITCH - WITH REMOTE AUDIO/CLIMATE CONTROL
Removal and Installation
All vehicles 1. Remove the driver side air bag module.
Expedition
2. Remove the speed control switch.
1 Disconnect the electrical connector.
2 Remove the screws.
Navigator
3. Remove the horn switch.
1 Disconnect the electrical connector.
2 Remove the bolts.
4. Remove the speed control switch.
1 Disconnect the wiring harness locators.
2 Remove the screws.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Speed Control Switch - With Remote Audio/Climate Control > Page 10235
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Speed Control Switch - With Remote Audio/Climate Control > Page 10236
Cruise Control Switch: Service and Repair Speed Control Switch - Without Remote Audio/Climate
Control
SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROL
Removal and Installation
1. Remove the driver side air bag module.
2. Remove the speed control actuator switch.
1 Release the four (A) speed control actuator switch clips and remove the (B) speed control
actuator switch.
2 Disconnect the speed control actuator switch electrical connector.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Locations
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Locations > Page 10241
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10246
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10247
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10248
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10249
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10250
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10251
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10252
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10253
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10254
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10255
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10256
Cigarette Lighter: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10257
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10258
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10259
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10260
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10261
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10262
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10263
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10264
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10265
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10266
Cigarette Lighter: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10267
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams
> Page 10271
Clock: Description and Operation
CLOCK
The stand-alone electric analog clock, available in the Navigator only, is centrally located on the
instrument panel and displays time in a 12 hour format. The clock is backlit when the headlamps
and parking lamps are on. The Expedition clock is integrated into the radio.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview
Clock: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern by operating the electric clock.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical and/or electrical damage using the chart. 3. If an
obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step. 4. If the concern is not visually evident, proceed to the Symptom
Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview > Page 10274
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Initial Inspection and Diagnostic Overview > Page 10275
Clock: Pinpoint Tests
PINPOINT TEST A: THE CLOCK OPERATION IS ERRATIC/INOPERATIVE
Test A1
Test A2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Page 10276
Clock: Service and Repair
CLOCK
REMOVAL
1. Remove the instrument cluster center finish panel.
2. Disconnect the electrical connector.
3. Pry the retaining clips away from the clock and remove the clock from the instrument cluster
center finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection > Page 10277
73III Automotive Meter
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment
Compass: Adjustments Compass Zone Adjustment
With Message Center
COMPASS ZONE ADJUSTMENT - WITH MESSAGE CENTER
1. NOTE: The compass zone setting is preset from the factory to Zone 8.
Determine which magnetic zone you are in for your geographic location.
2. Start the engine. 3. Press the message center switch INFO button until the compass information
is displayed. 4. Press and hold the SETUP and RESET buttons until the message center display
changes to show the current zone setting. 5. Press the SETUP button repeatedly until the correct
zone setting is displayed in the message center. 6. To exit the zone setting mode, and the lock in
the change, press and release the RESET button.
Without Message Center
COMPASS ZONE ADJUSTMENT - WITHOUT MESSAGE CENTER
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 10283
1. NOTE: The compass zone setting is preset from the factory to Zone 8.
Determine which magnetic zone you are in for your geographic location.
2. Start the engine. 3. Press the TRIP/RESET button, hold for 6 seconds and release. ZONE will
appear in the instrument cluster display. 4. Press and release the TRIP/RESET button until the
desired zone number appears. 5. When the desired zone number appears in the instrument cluster
display, hold the TRIP/RESET button down to set the new zone number. The
instrument cluster display will return to the normal mode when the TRIP/RESET button has not
been pressed for 6 seconds.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 10284
Compass: Adjustments Vehicle Demagnetizing
VEHICLE DEMAGNETIZING
CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a
cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth
covers the front third and the entire width of the roof.
NOTE:
- The demagnetizing process requires the use of a demagnetizing coil commonly used by television
service technicians to demagnetize television tubes.
- To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the
demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained
in the vehicle.
- During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite
the handle) is closest to the vehicle surface.
1. Demagnetize the front third of the vehicle roof.
1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle.
2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger
side, demagnetize the front third of the roof closest to the windshield using a constant circular
motion. Keep the circles radius within 30 cm (12 in) while sweeping across the entire surface of the
roof closest to the windshield. Continue the circular motion 4 times.
3 After the 4th pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from
the vehicle.
4 Turn the demagnetizer off.
2. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5
cm (1 in).
Demagnetize the inside rear view mirror mounting pad. 1
Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle.
2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside
rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft)
away from the vehicle.
3 Turn the demagnetizer off.
3. Carry out the Compass Zone Adjustment procedure. See: Compass Zone Adjustment 4. Carry
out the Calibration Adjustment procedure. See: Compass Calibration
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 10285
Compass: Adjustments Compass Calibration
With Message Center
COMPASS CALIBRATION - WITH MESSAGE CENTER
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects
or structures. Switch off all non-essential
electrical accessories (rear window defrost, heater A/C, map lamps, wiper, etc.) and make sure all
the doors are closed.
Start the vehicle.
2. Press the RESET control button to start the compass calibration function. 3. Slowly drive the
vehicle in a circle (less than 5 km/h ) until the CIRCLE SLOWLY TO CALIBRATE display changes
to CALIBRATION
COMPLETE. It will take up 5 circles to complete the compass calibration.
Without Message Center
COMPASS CALIBRATION - WITHOUT MESSAGE CENTER
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects
or structures. Switch off all non-essential
electrical accessories (rear window defrost, heater A/C, map lamps, wiper, etc.) and make sure all
the doors are closed.
Start the vehicle.
2. Enter the compass calibration mode by pressing and holding the TRIP/RESET button for 8
seconds. The instrument cluster display will then show
CAL.
3. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CAL turns off in the
instrument cluster display (approximately 5 circles).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10291
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10292
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10293
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10294
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10295
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10296
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10297
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10298
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10299
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10300
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10301
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10302
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10303
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. NOTE: For Expedition headlamp and dimmer switch removal, refer to Lighting and Horns.
Remove the instrument panel finish panel. Disconnect the electrical connectors.
2. Depress the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 10311
Door Switch: Locations Door Ajar Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 10312
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 10313
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 10314
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch > Page 10317
Door Switch: Diagrams Door Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch > Page 10318
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Page 10319
Door Switch: Service and Repair
DOOR AJAR SWITCH
Removal and Installation
1. Remove the door latch.
2. Remove the door ajar switch.
1 Release the door lock actuator locking tab.
2 Remove the door lock actuator.
3 Release the locking tab and remove the door ajar switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 10323
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 10324
Driver/Vehicle Information Display: Description and Operation
INFORMATION AND MESSAGE CENTER
The message center display is a green vacuum fluorescent, fixed format display. The message
center is a 2-line display integrated into the center of the instrument cluster and is controlled by the
message center switches. Refer to the Owner's Literature for operating instructions.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview
Principles of Operation
PRINCIPLES OF OPERATION
The message center is a vacuum fluorescent display, part of the instrument cluster. The message
center electronic functions use both hardwired, and controller area network (CAN) to transmit and
receive information. As a technician, it is very important to understand:
- where the input (command) originates.
- all the information (messages) necessary in order for a feature to operate.
- which module(s) receive(s) the input or command message.
- if the module that received the input (message) controls the output of the feature, or if it outputs a
message over the CAN to another module.
- which module controls the output of the feature.
The message center provides the following features:
- information displays
- setup displays
- warning messages
- system check messages
The message center information can be selected through a set of 3 buttons:
- INFO
- SETUP
- RESET
Information Displays The information displays are non-timed modes. The selected mode remains
on until the driver depresses a message center button to change the mode or it is overridden by
another mode. The information display modes are:
- odometer
- trip odometer
- compass
- distance to empty
- average fuel economy
Setup Displays The setup displays are timed modes and terminate after a finite interval. The setup
display modes are:
- system check
- English/metric units
- power liftgate on/off (if equipped)
- running board auto in/out (if equipped)
- easy exit seat (if equipped)
- autolamp delay
- language
Warning Messages The warning messages are single cycle, non-resettable and repetitive warning
messages. The single cycle warning messages are:
- CHECK SUSPENSION
- CHECK COMPASS MODULE
- NO RESPONSE COMPASS
- ENGINE TEMP DATA
- COMPASS DATA ERROR
- DOOR SENSOR DATA ERROR
- CHARGING SYSTEM DATA ERROR
- CHECK PARK ASSIST
- CHECK FUEL CAP
- LOW WASHER FLUID LEVEL
The single cycle warning messages display once whenever the ignition switch is turned to ON or a
fault occurs in a system and can be cleared by pressing the RESET button.
The repetitive warning messages are:
- LOW BRAKE FLUID LEVEL
- CHECK CHARGING SYSTEM
- LOW FUEL LEVEL
- LOW OIL PRESSURE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10327
- CHECK ENGINE TEMPERATURE
- TEMPORARY 4x4 HIGH
- CHECK ADV/TRAC
The repetitive warning messages are displayed at a fixed interval whenever the ignition switch is
turned ON or is in the ACC position. To remove a repetitive warning message, press the RESET
button. The message only reoccurs after 10 minutes or until the warning condition is corrected.
The non-resettable warning messages display whenever the ignition switch is turned to ON and a
fault occurs in a system. The fault must be corrected to clear the non-resettable warning
messages.
The non-resettable warning messages are:
- DOOR AJAR
- STOP ENGINE SAFELY
- REDUCED ENGINE POWER
- ENGINE FAILSAFE MODE
- PARK ASSIST ON/OFF
- TRAIN LF TIRE
- TRAIN LR TIRE
- TRAIN RF TIRE
- TRAIN RR TIRE
- TRAIN SPARE TIRE
- TIRE TRAINING MODE COMPLETE
- TIRES NOT TRAINED
- PARK BRAKE ENGAGED
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link
connector (DLC) and select the vehicle to be tested from the
diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: Check that the program card is correctly installed.
- Check the connections to the vehicle.
- Check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
- CAN circuit fault; all electronic control units no response/not equipped, refer to Information Bus
(Module Communications Network).
- No response/not equipped for the instrument cluster, refer to Instrument Cluster.
- System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the
continuous DTCs, and carry out self-test diagnostics for the instrument cluster.
7. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic
Trouble Code (DTC) Index. See: Diagnostic Trouble
Code Descriptions
8. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10328
B1209 / U2013
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10329
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10330
Symptom Chart (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10331
Symptom Chart (Part 3)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10332
Symptom Chart (Part 4)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10333
Symptom Chart (Part 5)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10334
Driver/Vehicle Information Display: Pinpoint Tests
Test A: The Message Center Is Not Operating Correctly
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY
A1
Test B: The Compass Is Inoperative
PINPOINT TEST B: THE COMPASS IS INOPERATIVE
B1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10335
B1-B3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10336
B3 Continued
Test C: The Compass Is Inaccurate
PINPOINT TEST C: THE COMPASS IS INACCURATE
C1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10337
C2-C3
Test D: The Message Center Switch Does Not Operate Correctly
PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
D1-D3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10338
D3-D5
Test E: The Power Liftgate Display Is Inoperative
PINPOINT TEST E: THE POWER LIFTGATE DISPLAY IS INOPERATIVE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10339
E1-E3
Test F: The Power Running Boards Display Is Inoperative
PINPOINT TEST F: THE POWER RUNNING BOARDS DISPLAY IS INOPERATIVE
F1-F3
Test G: The Park Assist On/Off Display Is Inoperative
PINPOINT TEST G: THE PARK ASSIST ON/OFF DISPLAY IS INOPERATIVE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10340
G1
G2-G3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Page 10341
Driver/Vehicle Information Display: Service and Repair
MESSAGE CENTER SWITCH
Removal and Installation
1. Remove the instrument cluster finish panel.
2. NOTE: Navigator shown, Expedition similar.
Press the tabs and remove the message center switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Page 10342
Special Tool(s)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator >
Component Information > Description and Operation
Fuel Filler Cap Warning Indicator: Description and Operation
FUEL CAP INDICATOR LAMP
The fuel cap indicator lamp (FCIL) is a communications network message sent by the PCM. The
PCM sends the message to illuminate the lamp when the strategy determines that there is a failure
in the vapor management system due to the fuel filler cap not being sealed properly. This would be
detected by the inability to pull vacuum in the fuel tank, after a fueling event.
NOTE: The FCIL on the Crown Victoria/Grand Marquis, Explorer Sport Trac, and Ranger is a
dedicated output signal that is controlled by the PCM.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump Module and Reservoir
Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump Module and Reservoir > Page 10350
Fuel Gauge Sender: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump Module and Reservoir > Page 10351
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump Module and Reservoir > Page 10352
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 10353
Fuel Gauge Sender: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 10354
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped)
system is being serviced, the supplemental restraint system (SRS) must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located below the RH side of the instrument panel, open the kick panel cover and
remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front
of any air bag module when the
battery ground cable is connected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10360
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.
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)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
module deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10361
NOTE:
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover
and remove the restraints control
module (RCM) fuse F1.19 (10A) from the CJB.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
or replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The front impact severity sensor is located at the bottom of the hood latch support bracket.
The first row side impact sensors (if equipped) are located in the first row doors, behind the door
trim panel.
The second row side impact sensors (if equipped) are located at or near the base of the C-pillars.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute.
7. Remove the two steering wheel back cover plugs (one shown).
8. Remove the two driver air bag module bolts (one shown).
Expedition vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10362
9. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Navigator vehicles
10. Disconnect the driver air bag module.
- Release the two tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting.
11. Release the tab and disconnect the driver air bag module accessories electrical connector at
the top of the clockspring and remove the driver air
bag module.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10363
12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
13. While pushing in on the two glove compartment door tabs, position the glove compartment
downward.
14. NOTE: The Expedition is shown, the Navigator is similar.
Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10364
If the safety canopy 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 safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
17. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row passenger side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row passenger side safety belt guide.
18. Remove the passenger side C-pillar trim panel.
1 Separate the weather-stripping along the passenger side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the passenger side C-pillar trim panel.
19. Disconnect the passenger side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10365
20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy electrical connector.
21. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt
guide cover is damaged or if it does not remain closed,
install a new shoulder safety belt guide cover.
Remove the second row driver side safety belt guide. 1
Release the retaining tab at each side and open the safety belt guide cover.
2 Remove the nut.
3 Remove the second row driver side safety belt guide.
22. Remove the driver side C-pillar trim panel.
1 Separate the weather-stripping along the driver side C-pillar trim panel.
2 Remove the bolt cover and bolt.
3 Pull out to release the retainers and remove the driver side C-pillar trim panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10366
23. Disconnect the driver side safety canopy electrical connector.
24. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy electrical connector.
All vehicles 25. Install the RCM fuse F1.19 (10A) to the CJB. 26. Connect the battery ground cable.
Reactivation
All vehicle 1. Remove the RCM fuse F1.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy electrical connector.
4. Connect the driver side safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10367
5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the driver side C-pillar trim panel. 1
Position the driver side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the driver side C-pillar trim panel.
6. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row driver side safety belt guide. 1
Position the second row driver side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy electrical connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10368
8. Connect the passenger side safety canopy electrical connector.
9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C
pillar upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy module deployment.
Install the passenger C-pillar trim panel. 1
Position the passenger side C-pillar trim panel and push in, engaging the retainers.
2 Install the bolt and bolt cover.
3 Install the weather-stripping along the passenger side C-pillar trim panel.
10. NOTE:
- Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is
damaged or if it does not remain closed, install a new shoulder safety belt guide cover.
- Make sure the safety belt is not twisted prior to installation.
Install the second row passenger side safety belt guide. 1
Position the second row passenger side safety belt guide.
2 Install the nut.
3 Close the safety belt guide cover.
All vehicles
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10369
11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
12. NOTE: The Expedition is shown, the Navigator is similar.
Connect the passenger air bag module electrical connector.
13. Close the glove compartment.
14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Navigator vehicles
15. Connect the driver air bag module accessories electrical connector to the connector end at the
top of the clockspring.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10370
16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel.
Expedition vehicles
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
All vehicles
18. Install the two driver air bag module bolts (one shown).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10371
19. Install the two steering wheel back cover plugs (one shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F1.19 (10A) to the CJB and
close the cover.
23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
24. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 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.
Vehicles with safety canopies 25. Check the active restraint system for correct operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 10372
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 an SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
will need to be repaired before diagnosis can continue.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb
Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb
INSTRUMENT CLUSTER BULB
Removal and Installation
1. Remove the instrument cluster.
2. Remove the instrument cluster illumination bulbs. 3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 10377
Instrument Panel Bulb: Service and Repair Warning Indicator Bulb
WARNING INDICATOR BULB
Removal and Installation
All vehicles 1. Remove the instrument cluster.
Expedition
2. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise
and lift it out from the instrument cluster.
Remove the warning indicator bulb(s) in question.
Navigator
3. Release the clips and remove the rear cover.
4. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise
and lift it out from the instrument cluster.
Remove the warning indicator bulb(s) in question.
All vehicles 5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-22-10 > Nov > 05 >
Instruments - Outside Temperature Display Inaccurate
Instrument Panel Control Module: Customer Interest Instruments - Outside Temperature Display
Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-9-12 > May > 05 >
Instruments - 'Check Park Assist' Displayed
Instrument Panel Control Module: Customer Interest Instruments - 'Check Park Assist' Displayed
TSB 05-9-12
05/16/05
"CHECK PARK ASSIST" DISPLAYED IN MESSAGE CENTER - VEHICLES BUILT PRIOR TO
4/1/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built prior to 4/1/2005 and equipped with a
message center, may display a "Check Park Assist" message with no diagnostic trouble codes
(DTCs) present in the message center.
ACTION Reprogram the cluster to the latest calibration using WDS release B37.2 or higher.
Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050912A 2005 Expedition/Navigator 0.3 Hr.
Check For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With
12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14026 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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: > 05-22-10
> Nov > 05 > Instruments - Outside Temperature Display Inaccurate
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Outside
Temperature Display Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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: > 05-9-12 >
May > 05 > Instruments - 'Check Park Assist' Displayed
Instrument Panel Control Module: All Technical Service Bulletins Instruments - 'Check Park Assist'
Displayed
TSB 05-9-12
05/16/05
"CHECK PARK ASSIST" DISPLAYED IN MESSAGE CENTER - VEHICLES BUILT PRIOR TO
4/1/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built prior to 4/1/2005 and equipped with a
message center, may display a "Check Park Assist" message with no diagnostic trouble codes
(DTCs) present in the message center.
ACTION Reprogram the cluster to the latest calibration using WDS release B37.2 or higher.
Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050912A 2005 Expedition/Navigator 0.3 Hr.
Check For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With
12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14026 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-21-6 > 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 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 10404
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 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 10405
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 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 10411
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 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 10412
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 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Description and Operation
Low Tire Pressure Indicator: Description and Operation
TIRE PRESSURE MONITORING SYSTEM (TPMS)
When the Tire Pressure Monitoring System warning light is lit, one or more of your tires is
significantly under-inflated. You should stop and check your tires as soon as possible, and inflate
them to the proper pressure as indicated on the vehicle's tire information placard (label). Driving on
a significantly under-inflated tire causes the tire to overheat and can eventually lead to tire failure.
Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling
and stopping ability. Even if your vehicle is equipped with a Tire Pressure Monitoring System, it is
still Important that you manually check the inflation pressure of your tires regularly. Each tire,
including the spare, should be checked monthly when cold and set to the recommended inflation
pressure which can be found on either the tire label or certification label which is located on the
B-Pillar or the edge of the driver's door.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Description and Operation > Page 10416
Low Tire Pressure Indicator: Service and Repair
Sensor Training (Reset Procedure)
NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones and remote
transmitters, power inverters and portable entertainment equipment.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to
the RUN position three times, ending in the RUN position. Do not wait more than one minute
between each key cycle.
3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than one minute
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LF TIRE", place the magnet on the valve stem of the LF tire pressure sensor. The horn will
sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the VSM (TPMS module integral to VSM) does not recognize any one of the four tire
pressure sensors during the tire training procedure, the horn will sound twice and the message
center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be
repeated.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will display "TIRE TRAINING MODE COMPLETE".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
This vehicle is not equipped with a Maintenance Required Lamp/Indicator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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)
The MIL notifies the driver that the powertrain control module (PCM) has detected an OBD
emission-related component or system fault. When this occurs an OBD diagnostic trouble code
(DTC) will be set.
^ The MW is located in the instrument cluster and is labeled CHECK ENGINE SERVICE ENGINE
SOON or the ISO standard engine symbol.
^ The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
^ For applications with a dedicated hard wire MIL circuit the PCM will illuminate the MIL until a
profile ignition pickup (PIP) signal is detected. For 2OO5 the following vehicles use a hard wire
circuit: Crown Victoria/Grand Marquis Explorer Sport Trac and Ranger.
^ The MIL will remain illuminated after instrument cluster prove out if:
^ an emission related concern and DTC exists.
^ no PIP signal is detected (applications with a dedicated hard-wire MIL circuit). The PIP signal is
generated in the PCM using the crankshafi position (CKP) sensor. For these applications the MIL
can be helpful in diagnosing a no start.
^ the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
^ the PCM is operating in the Hardware Limited Operation Strategy (KLOS).
^ the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit).
^ The MIL remains off during the instrument cluster prove out if:
^ an indicator or instrument cluster concern is present.
^ the MIL circuit is open (applications with a dedicated hard wire MIL circuit).
^ To turn off the MIL afier a repair a reset command from the diagnostic tool must be sent or 3
consecutive drive cycles must be completed without a fault.
^ For all MIL concerns go to Symptom Charts.
^ If the MIL flashes at a steady rate a severe misfire condition may exist.
^ If the MIL flashes erratically the PCM can reset while cranking if the battery voltage is low.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
This vehicle is not equipped with a Oil Change Reminder Lamp.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
View 151-4 (Engine, Front)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 10429
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component
Information > Technical Service Bulletins > Customer Interest for Outside Temperature Display: > 05-22-10 > Nov > 05 >
Instruments - Outside Temperature Display Inaccurate
Outside Temperature Display: Customer Interest Instruments - Outside Temperature Display
Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Outside Temperature Display: > 05-22-10 >
Nov > 05 > Instruments - Outside Temperature Display Inaccurate
Outside Temperature Display: All Technical Service Bulletins Instruments - Outside Temperature
Display Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 > Oct > 06 > Parking Assist System Speaker Inop./DTC C1742/C1743
Parking Assist Warning Indicator: Customer Interest Parking Assist System - Speaker Inop./DTC
C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 > Oct > 06 > Parking Assist System Speaker Inop./DTC C1742/C1743 > Page 10451
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-20-5 > Oct > 06 > Parking
Assist System - Speaker Inop./DTC C1742/C1743
Parking Assist Warning Indicator: All Technical Service Bulletins Parking Assist System - Speaker
Inop./DTC C1742/C1743
TSB 06-20-5
10/16/06
PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743
FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150
2004-2007 F-250, F-350
MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner
ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS)
may experience low or no audible sound due to speaker issues related to the RSS. The speaker is
attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder
Circuit Fault) and/or C1743 (Rear Sounder Short).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible
warning condition may exist as well.
2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker
in Speaker Kit. Follow instructions in Speaker Kit.
3. Clear DTCs and repeat check for DTCs C1742 and/or C1743.
4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete.
5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13
Pinpoint Test F.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062005A 2004-2006 Expedition: 1.2 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2007 Super Duty 0.6 Hr.
250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With
31012AR, 31012AL, 31012AT)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-20-5 > Oct > 06 > Parking
Assist System - Speaker Inop./DTC C1742/C1743 > Page 10457
062005A 2004-2005 1.1 Hrs.
Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not
Use With 31012AR, 31012AL, 31012AT)
062005A 2006 Explorer/Mountaineer: 1.3 Hrs.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR,
31012AL, 31012AT)
062005A 2004-2006 F-150: Replace 0.5 Hr.
Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL,
31012AT)
062005A 2004-2006 Escape, 0.8 Hr.
2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Five 1.3 Hrs.
Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use
With 31012AR, 31012AL, 31012AT)
062005A 2005-2007 Freestyle: 0.7 Hr.
Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR
31012AL, 31012AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K864 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Warning Indicator: >
05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt Chime
Seat Belt Control Module: All Technical Service Bulletins Restraints/Instruments - Can't Disable
Seat Belt Chime
TSB 05-9-17
05/16/05
INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME
(BELTMINDER)
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
This article supersedes TSB 05-04-02 to update the TSB action information.
ISSUE Some 2005 Expedition/Navigator vehicles may exhibit an inability to disable the BeltMinder
function, following procedures listed in the Workshop Manual or the Owner Guide. The BeltMinder
function operates normally, but can not be turned off (if desired by the customer).
ACTION Replace the restraint control module (RCM), which includes the software to disable the
BeltMinder. Refer to Workshop Manual Section 501-20B to replace the RCM. Then follow
Workshop Manual (Section 413-09) or the Owner Guide (3rd Printing) procedures to disable the
BeltMinder function.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050917A 2005 Expedition: Replace 1.0 Hr.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B, 14056D1C,
14056DZR)
050917B 2005 Navigator: Replace 1.2 Hrs.
The Restraints Control Module (Includes Time To Depower And Repower The Supplemental
Restraints System And Disable The BeltMinder) (Do Not Use With 14056D, 14056D1B,
14056DZR)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B321 42
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Warning Indicator: >
05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt Chime > Page 10463
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Warning Indicator: >
05-9-17 > May > 05 > Restraints/Instruments - Can't Disable Seat Belt Chime > Page 10469
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Technical Service Bulletins > Page 10470
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations > Page 10474
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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: > 05-22-10 > Nov > 05 > Instruments - Outside Temperature Display Inaccurate
Instrument Panel Control Module: Customer Interest Instruments - Outside Temperature Display
Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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: > 05-9-12 > May > 05 > Instruments - 'Check Park Assist' Displayed
Instrument Panel Control Module: Customer Interest Instruments - 'Check Park Assist' Displayed
TSB 05-9-12
05/16/05
"CHECK PARK ASSIST" DISPLAYED IN MESSAGE CENTER - VEHICLES BUILT PRIOR TO
4/1/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built prior to 4/1/2005 and equipped with a
message center, may display a "Check Park Assist" message with no diagnostic trouble codes
(DTCs) present in the message center.
ACTION Reprogram the cluster to the latest calibration using WDS release B37.2 or higher.
Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050912A 2005 Expedition/Navigator 0.3 Hr.
Check For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With
12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14026 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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: > 05-22-10 > Nov > 05 > Instruments - Outside Temperature Display Inaccurate
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Outside
Temperature Display Inaccurate
TSB 05-22-10
11/14/05
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE
FORD: 2005 Expedition
ISSUE Some 2005 Expeditions built before 4/1/2005 may have an outside air temperature display
that is inaccurate, slow to update, or erratically displays -40° F (-40° C).
ACTION Reprogram the instrument cluster to the latest calibration using WDS release B39.6 or
higher. Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052210A 2005 Expedition: Check 0.3 Hr.
For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With 12651D,
12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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: > 05-9-12 > May > 05 > Instruments - 'Check Park Assist' Displayed
Instrument Panel Control Module: All Technical Service Bulletins Instruments - 'Check Park Assist'
Displayed
TSB 05-9-12
05/16/05
"CHECK PARK ASSIST" DISPLAYED IN MESSAGE CENTER - VEHICLES BUILT PRIOR TO
4/1/2005
FORD: 2005 Expedition
LINCOLN: 2005 Navigator
ISSUE Some 2005 Expedition/Navigator vehicles built prior to 4/1/2005 and equipped with a
message center, may display a "Check Park Assist" message with no diagnostic trouble codes
(DTCs) present in the message center.
ACTION Reprogram the cluster to the latest calibration using WDS release B37.2 or higher.
Calibration files may also be obtained at the website.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050912A 2005 Expedition/Navigator 0.3 Hr.
Check For Diagnostic Trouble Codes And Reprogram The Instrument Cluster (Do Not Use With
12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14026 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component
Information > Description and Operation
Seat Belt Reminder Buzzer: Description and Operation
Belt Minder (if equipped)
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently
sounding a chime and illuminating the safety belt warning lamp in the instrument cluster.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Description and Operation
Seat Belt Reminder Lamp: Description and Operation
Belt Minder (if equipped)
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently
sounding a chime and illuminating the safety belt warning lamp in the instrument cluster.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. NOTE: For Expedition headlamp and dimmer switch removal, refer to Lighting and Horns.
Remove the instrument panel finish panel. Disconnect the electrical connectors.
2. Depress the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Ajar Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10511
Door Switch: Locations Door Ajar Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10512
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10513
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10514
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10517
Door Switch: Diagrams Door Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10518
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Page 10519
Door Switch: Service and Repair
DOOR AJAR SWITCH
Removal and Installation
1. Remove the door latch.
2. Remove the door ajar switch.
1 Release the door lock actuator locking tab.
2 Remove the door lock actuator.
3 Release the locking tab and remove the door ajar switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module and Reservoir
Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir
FUEL PUMP MODULE AND RESERVOIR
Fuel Pump Module And Reservoir
The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge
check valve that maintains the system pressure after the ignition key has been turned off to
minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle
maneuvers with low tank fill levels.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page
10524
Fuel Gauge Sender: Description and Operation Fuel Pump Module
FUEL PUMP MODULE
Fuel Pump Module (For Returnable Fuel Systems)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page
10525
Mechanical Returnless Fuel Pump Module (FPM)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module and Reservoir > Page
10526
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel
pump is located inside the FP module reservoir and supplies fuel through the FP module manifold
to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and
a check valve located in the manifold outlet maintains system pressure when the fuel pump is not
energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir
and prime the fuel pump during the initial fill.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 10527
Fuel Gauge Sender: Service and Repair
FUEL PUMP MODULE
Wrench, Fuel Tank Sender Unit
Special Tool(s)
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or
near any fuel-related component. Highly flammable mixtures are always present and can be
ignited. Failure to follow these instructions may result in personal injury.
1. Remove the fuel tank.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 10528
2. Disconnect the fuel and vapor tubes from the fuel pump module.
3. Using the special tool, remove the fuel pump lock ring.
4. CAUTION:
- Note the location of the fuel pump alignment tabs.
- Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor.
Remove the fuel pump module assembly. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations
View 151-15 (LH A-Pillar)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations > Page 10532
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information >
Service and Repair
Shift Indicator: Service and Repair
SELECTOR LEVER INDICATOR BULB
Removal and Installation
1. Push down the selector lever boot.
2. Push down the selector lever collar.
3. Remove the selector lever knob screw.
- Remove the selector lever knob.
4. Detach the selector lever indicator bezel.
- Disconnect the electrical connector.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component
Information > Description and Operation
Temperature Sensor (Gauge): Description and Operation
Temperature Gauge
The PCM receives the engine coolant temperature status through hardwired circuitry to the engine
coolant temperature (ECT) sensor. The instrument cluster receives the engine coolant temperature
data from the PCM through the SCP communication network. The instrument cluster
microprocessor monitors the engine coolant temperature data received from the PCM and
commands the temperature gauge indication with a corresponding movement of the pointer.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Description and Operation
Low Tire Pressure Indicator: Description and Operation
TIRE PRESSURE MONITORING SYSTEM (TPMS)
When the Tire Pressure Monitoring System warning light is lit, one or more of your tires is
significantly under-inflated. You should stop and check your tires as soon as possible, and inflate
them to the proper pressure as indicated on the vehicle's tire information placard (label). Driving on
a significantly under-inflated tire causes the tire to overheat and can eventually lead to tire failure.
Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling
and stopping ability. Even if your vehicle is equipped with a Tire Pressure Monitoring System, it is
still Important that you manually check the inflation pressure of your tires regularly. Each tire,
including the spare, should be checked monthly when cold and set to the recommended inflation
pressure which can be found on either the tire label or certification label which is located on the
B-Pillar or the edge of the driver's door.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Description and Operation > Page 10543
Low Tire Pressure Indicator: Service and Repair
Sensor Training (Reset Procedure)
NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation.
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones and remote
transmitters, power inverters and portable entertainment equipment.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to
the RUN position three times, ending in the RUN position. Do not wait more than one minute
between each key cycle.
3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than one minute
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LF TIRE", place the magnet on the valve stem of the LF tire pressure sensor. The horn will
sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the VSM (TPMS module integral to VSM) does not recognize any one of the four tire
pressure sensors during the tire training procedure, the horn will sound twice and the message
center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be
repeated.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will display "TIRE TRAINING MODE COMPLETE".
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Module > Component Information > Application and ID
Tire Pressure Module: Application and ID
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Module > Component Information > Application and ID > Page 10547
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
1. NOTE: The Tire Pressure Monitoring System (TPMS) is integral to the Vehicle Security Module
(VSM) and is not serviced separately.
Remove the VSM.
2. To install, reverse the removal procedure. 3. Reconfigure the VSM module. 4. Train the tire
pressure sensors. 5. Clear the DTCs. Repeat the self-test.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
Special Tool(s)
CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve
stem damage and loss of tire pressure.
Removal
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
The Tire Pressure Monitoring System (TPMS) will not operate correctly if black-colored tire
pressure sensors are installed.
1. Remove the wheel and tire assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Page 10551
2. CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
The above illustration and table indicates parts making up the tire pressure monitoring sensor
assembly.
3. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original
valve stem core. If the original valve stem core is
damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in
corrosion and the Possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and push the sensor
by hand into the tire (with the cap on).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Page 10552
4. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
5. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
6. Remove the tire pressure sensor from the tire. 7. Remove and discard the grommet from the tire
pressure sensor.
Installation
NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new
components, use only this tire pressure sensor.
TPMS will not operate correctly if black-colored tire pressure sensors are installed.
1. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure
sensor, undertightening can cause air leaks.
Install a new grommet on the tire pressure sensor.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Page 10553
2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside and inside bead of the tire to the rim.
3. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately two clockwise turns after
the nut has been tightened by hand.
Push the side wall of the tire and install the tire pressure sensor. Tighten the nut.
4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that
accurate values are obtained.
CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air
chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks.
CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not
recommended to use air chucks with long shanks.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Page 10554
Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure.
CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure
sensors. Do not use brass-threaded valve caps with the tire pressure sensors.
Inflate the tire to the pressure specified on the safety certification sticker located on the driver or
door pillar.
5. Install the wheel and tire assembly. 6. Train the tire pressure sensors.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp
> Component Information > Description and Operation
Transmission Shift Position Indicator Lamp: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair
Ambient Light Sensor: Service and Repair
PHOTOCELL AND AMPLIFIER
Removal and Installation
All vehicles 1. Disconnect the battery ground cable.
Expedition
2. Remove the photocell and bezel from the defroster grille.
- Disconnect the electrical connector.
3. Remove the screws and the photocell and amplifier.
Navigator
4. Remove the defroster grille.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair >
Page 10562
5. Remove the screws and the photocell.
- Disconnect the electrical connector.
All vehicles 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations
> Page 10567
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations
> Page 10568
Backup Lamp Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations
> Page 10569
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 10573
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 10574
Backup Lamp Switch: Service and Repair
REVERSING LAMP
Removal and Installation
1. Remove the screws and the liftgate pull handle.
2. Remove the liftgate trim panel.
- Remove the water shield.
3. Release the tabs and remove the reversing lamp.
- Disconnect the reversing lamp.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10579
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10580
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10581
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10582
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10583
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10584
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10585
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10586
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10587
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10588
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10589
Brake Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10590
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10591
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10592
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10593
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10594
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10595
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10596
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10597
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10598
Brake Lamp: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10599
Brake Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10600
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Brake Lamp: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom
Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10603
Symptom Chart
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10604
Brake Lamp: Pinpoint Tests
Test H: The Stoplamps Are Inoperative
PINPOINT TEST H: THE STOPLAMPS ARE INOPERATIVE
H1
H1-H2
Test I: One or More Stoplamps Are Inoperative
PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10605
I1
I1-I4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10606
I4-I5
Test J: The Stoplamps Are on Continuously
PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY
J1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10607
J2-J6
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10608
J6 Continued
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
10609
73III Automotive Meter
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10613
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10614
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10615
Brake Light Switch: Service and Repair
BRAKE PEDAL POSITION (BPP) SWITCH
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the BPP switch.
1 Disconnect the electrical connector.
2 Remove the self-locking pin and the BPP switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams
Ash Tray Lamp: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Locations
Courtesy Lamp Relay: Locations
View 151-12 (Dash Panel)
The interior lamp relay is located in the instrument cluster and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service
and Repair
Interior Light Switch: Service and Repair
SWITCH - INTERIOR LAMP
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 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay
Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Headlamp Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 10640
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 10641
Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Ignition Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 10642
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay > Page 10645
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay
Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Headlamp
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 10648
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 10649
Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Ignition
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 10650
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. NOTE: For Expedition headlamp and dimmer switch removal, refer to Lighting and Horns.
Remove the instrument panel finish panel. Disconnect the electrical connectors.
2. Depress the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations
Battery Discharge Protection Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 10657
View 151-1 (Engine Compartment)
The battery saver relay is part of the central junction box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10662
Door Switch: Locations Door Ajar Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10663
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10664
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10665
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch >
Page 10668
Door Switch: Diagrams Door Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch >
Page 10669
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 10670
Door Switch: Service and Repair
DOOR AJAR SWITCH
Removal and Installation
1. Remove the door latch.
2. Remove the door ajar switch.
1 Release the door lock actuator locking tab.
2 Remove the door lock actuator.
3 Release the locking tab and remove the door ajar switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information >
Service and Repair
Fog/Driving Lamp Bulb: Service and Repair
FOG LAMP BULB
Removal and Installation
WARNING: The halogen bulb contains gas under pressure. The bulb may shatter if the glass
envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the
glass envelope. Failure to follow these instructions may result in personal injury.
NOTE:
- The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is
installed. Removing the bulb for an extended period of time may affect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and
reflector. Never turn on the fog lamp with the bulb removed from the fog lamp.
- Navigator shown, Expedition similar.
1. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position.
Disconnect the electrical connector and remove the fog lamp bulb.
2. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10678
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10679
Fog/Driving Lamp Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10680
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Page 10685
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Page 10686
Hazard Flasher Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information
> Locations > Page 10687
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection
Hazard Warning Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Page 10691
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Testing and Inspection > Page 10692
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
HEADLAMP BULB
Removal and Installation
All vehicles
WARNING: The halogen bulb contains gas under pressure. The bulb may shatter if the glass
envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the
glass envelope. Failure to follow these instructions may result in personal injury.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a new bulb
is installed. Removing the bulb for an extended period of time may affect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and
reflector. Never turn on the headlamp with the bulb removed from the headlamp.
1. Make sure that the headlamp switch and the ignition switch are in the OFF position.
Expedition
2. Loosen the headlamp retaining bolt.
3. Remove the bolts and the headlamp assembly.
- Disconnect the electrical connectors.
4. Remove the headlamp bulb protective cover(s).
1 Remove the low beam cover.
2 Remove the high beam cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 10697
5. CAUTION: Bulbs 9004 and 9007 look similar, but are not interchangeable.
Disconnect the electrical connector and remove the headlamp bulb.
Navigator high intensity discharge (HID) headlamp 6. Remove the front radiator air deflector.
7. Remove the three bolts and the headlamp assembly.
- Disconnect the electrical connectors.
8. Remove the headlamp bulb protective cover(s).
1 Remove the HID lamp cover.
2 Remove the high beam cover.
9. Disconnect the electrical connector and push the grommet into the headlamp assembly.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 10698
10. Release the spring tabs and remove the HID low beam bulb.
Navigator standard headlamp 11. Remove the front radiator air deflector.
12. Remove the three bolts and the headlamp assembly.
- Disconnect the electrical connectors.
13. Remove the headlamp bulb protective cover.
1 Low beam cover.
2 High beam cover.
14. CAUTION: Bulbs 9004 and 9007 look similar, but are not interchangeable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 10699
Disconnect the electrical connector and remove the headlamp bulb.
All vehicles 15. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information >
Application and ID
Headlamp Control Module: Application and ID
AUTOLAMPS
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10706
Headlamp Dimmer Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10707
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10708
Headlamp Dimmer Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10709
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10710
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10711
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 10715
Headlamp Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 10716
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Main Light Switch, Exterior Lamps
Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Main Light Switch, Exterior Lamps > Page 10719
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Main Light Switch, Exterior Lamps > Page 10720
Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Main Light Switch, Exterior Lamps > Page 10721
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Page 10722
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
Removal and Installation
All vehicles 1. Disconnect the battery ground cable.
Expedition
2. CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel.
NOTE: Use a thin-bladed tool to remove the headlamp switch bezel assembly.
Remove the headlamp switch and bezel assembly. Disconnect the electrical connectors.
Navigator
3. Remove the headlamp switch and bezel assembly.
- Disconnect the electrical connectors.
4. Remove the screws, release the tabs and remove the headlamp switch.
All vehicles 5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations >
Page 10726
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations >
Page 10727
High Beam Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations >
Page 10728
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10733
View 151-1 (Engine Compartment)
The horn relay is part of the central junction box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations
Interior Lighting Relay: Locations
View 151-12 (Dash Panel)
The interior lamp relay is located in the instrument cluster and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10741
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10742
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10743
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10744
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10745
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10746
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10747
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10748
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10749
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10750
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10751
License Plate Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10752
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10753
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10754
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10755
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10756
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10757
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10758
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10759
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10760
License Plate Lamp: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10761
License Plate Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10762
92-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10763
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Map Reading Lamp,
Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Map Reading Lamp,
Left Front > Page 10768
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Service and Repair > Lamp
Assembly - Map
Map Light: Service and Repair Lamp Assembly - Map
LAMP ASSEMBLY - MAP
Removal
1. Remove the map lamp assembly.
1 Carefully release the lamp lens.
2
NOTE: Identify the location of each screw to aid in the installation of the map lamp assembly.
Remove interior lamp screws.
3 Remove the map lamp assembly.
Installation
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Service and Repair > Lamp
Assembly - Map > Page 10771
Map Light: Service and Repair Bulb - Map Lamp
BULB - MAP LAMP
Removal
1. Remove the map lamp assembly.
2. Release the clip on the bulb(s) to be replaced.
3. Remove the map lamp bulb.
1 Remove the map lamp reflector.
2 Remove the map lamp bulb from the clips.
Installation
1. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10776
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10777
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10778
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10779
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10780
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10781
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10782
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10783
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10784
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10785
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10786
Marker Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10787
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10788
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10789
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10790
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10791
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10792
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10793
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10794
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10795
Marker Lamp: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10796
Marker Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10797
92-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10798
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
> Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
> Electronic Park Brake Release Relay > Page 10804
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams
> Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams
> Electronic Park Brake Release Relay > Page 10807
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Electronic Park Brake Release Relay
Parking Lamp Relay: Testing and Inspection Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Electronic Park Brake Release Relay > Page 10810
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Electronic Park Brake Release Relay > Page 10811
Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing
and Inspection > Electronic Park Brake Release Relay > Page 10812
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 10817
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 10818
Backup Lamp Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations > Page 10819
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Battery Discharge Protection Relay: Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 10823
View 151-1 (Engine Compartment)
The battery saver relay is part of the central junction box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Locations
Courtesy Lamp Relay: Locations
View 151-12 (Dash Panel)
The interior lamp relay is located in the instrument cluster and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay
Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Headlamp Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 10831
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 10832
Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Ignition Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 10833
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay > Page 10836
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay
Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Headlamp
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 10839
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 10840
Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Ignition
Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 10841
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10845
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10846
Fog/Driving Lamp Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10847
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 10851
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 10852
Hazard Flasher Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay >
Component Information > Locations > Page 10853
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module >
Component Information > Application and ID
Headlamp Control Module: Application and ID
AUTOLAMPS
For information regarding this component please refer to Body Control Module / Vehicle Security
Module (VSM).
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 10860
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 10861
High Beam Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 10862
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 10866
View 151-1 (Engine Compartment)
The horn relay is part of the central junction box (CJB) and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations
Interior Lighting Relay: Locations
View 151-12 (Dash Panel)
The interior lamp relay is located in the instrument cluster and is Not Serviceable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Electronic Park Brake Release Relay > Page 10874
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Diagrams > Electronic Park Brake Release Relay > Page 10877
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay
Parking Lamp Relay: Testing and Inspection Electronic Park Brake Release Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 10880
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 10881
Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 10882
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 10887
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 10890
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 10893
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 10894
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 10895
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 10899
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 10900
Turn Signal Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 10901
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Service and Repair
Ambient Light Sensor: Service and Repair
PHOTOCELL AND AMPLIFIER
Removal and Installation
All vehicles 1. Disconnect the battery ground cable.
Expedition
2. Remove the photocell and bezel from the defroster grille.
- Disconnect the electrical connector.
3. Remove the screws and the photocell and amplifier.
Navigator
4. Remove the defroster grille.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Service and Repair > Page 10906
5. Remove the screws and the photocell.
- Disconnect the electrical connector.
All vehicles 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
View 151-7 (Transmission - 4R75E)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 10910
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 10911
Backup Lamp Switch: Service and Repair
REVERSING LAMP
Removal and Installation
1. Remove the screws and the liftgate pull handle.
2. Remove the liftgate trim panel.
- Remove the water shield.
3. Release the tabs and remove the reversing lamp.
- Disconnect the reversing lamp.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
View 151-10 (behind Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10915
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10916
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical Brake Pedal Position (BPP) Switch
The 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 and for vehicle speed control
deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in
the following manner:
- BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle
brake pedal is applied.
- BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over
the data link to be received by the PCM.
- BPP switch is hard wired to the anti-lock brake system (ABS) traction control/stability assist
module. The stability module will interpret the BPP switch input along with other ABS inputs and
generate an output called the driver brake application (DBA) signal. The DBA signal is than sent to
the PCM and to other BPP signal users.
NOTE: On applications where the BPP switch is hard wired to the PCM and stop lamp circuit, if all
stop lamp 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 stop lamp bulbs has
failed.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10917
Brake Light Switch: Service and Repair
BRAKE PEDAL POSITION (BPP) SWITCH
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the BPP switch.
1 Disconnect the electrical connector.
2 Remove the self-locking pin and the BPP switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10922
Door Switch: Locations Door Ajar Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10923
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10924
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10925
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 10928
Door Switch: Diagrams Door Ajar Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 10929
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Page 10930
Door Switch: Service and Repair
DOOR AJAR SWITCH
Removal and Installation
1. Remove the door latch.
2. Remove the door ajar switch.
1 Release the door lock actuator locking tab.
2 Remove the door lock actuator.
3 Release the locking tab and remove the door ajar switch.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection
Hazard Warning Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 10934
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Testing and Inspection > Page 10935
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10939
Headlamp Dimmer Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10940
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10941
Headlamp Dimmer Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10942
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10943
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10944
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
View 151-12 (Dash Panel)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10948
Headlamp Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10949
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps
Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 10952
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 10953
Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 10954
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Page 10955
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
Removal and Installation
All vehicles 1. Disconnect the battery ground cable.
Expedition
2. CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel.
NOTE: Use a thin-bladed tool to remove the headlamp switch bezel assembly.
Remove the headlamp switch and bezel assembly. Disconnect the electrical connectors.
Navigator
3. Remove the headlamp switch and bezel assembly.
- Disconnect the electrical connectors.
4. Remove the screws, release the tabs and remove the headlamp switch.
All vehicles 5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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
SWITCH - INTERIOR LAMP
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 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10962
Turn Signal Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10963
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion
Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 10966
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 10967
Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 10968
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 10969
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Page 10970
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Testing and Inspection > Page 10971
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10976
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10977
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10978
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10979
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10980
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10981
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10982
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10983
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10984
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10985
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10986
Tail Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10987
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10988
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10989
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10990
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10991
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10992
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10993
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10994
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10995
Tail Lamp: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10996
Tail Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10997
92-2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10998
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions
Trailer Lamps: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11003
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11004
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11005
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11006
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11007
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear 900 .....................................................................................................
.......................................................................... Above door trim panel and headliner
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11008
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11009
Symbols Part 2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11010
Symbols Part 3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11011
Symbols Part 4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11012
Symbols Part 5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11013
Trailer Lamps: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11014
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11015
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11016
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Electrical short within the harness
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11017
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
2 Splice tape
3 Harness tape
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11018
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11019
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11020
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11021
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11022
Trailer Lamps: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 11023
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
VISUAL INSPECTION CHART
Electrical Central junction box (CJB) fuse(s): 10 (20A)
- 13 (10A)
- 29 (30A)
- 6 (10A)
- 2 (10A)
- 106 (30A)
- Circuitry
- Lamps
- Trailer tow battery charge relay
- Trailer tow park lamp relay
- Trailer tow electric brake controller
- CJB
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11026
Trailer Lamps: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Symptom Chart (Part 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11027
Trailer Lamps: Pinpoint Tests
Test X: The Trailer Lamps Are Inoperative
PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE
X1-X2
Test Y: The Individual Trailer Lamp Is Inoperative - RH Trailer Signal/Stoplamp/Hazard Flasher
Lamp
PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER
SIGNAL/STOPLAMP/HAZARD FLASHER LAMP
Y1
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11028
Y2-Y3
Test Z: The Individual Trailer Lamp Is Inoperative - LH Trailer Turn Signal/Stoplamp/Hazard
Flasher Lamp
PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER TURN
SIGNAL/STOPLAMP/HAZARD FLASHER LAMP
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11029
Z1-Z2
Z2-Z3
Tests AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps
PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS
AA1-AA2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11030
AA2-AA5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11031
AA5-AA7
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11032
AA8
Tests AB: Trailer Lamps Are Inoperative - Trailer Reversing Lamps
PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING
LAMPS
AB1-AB2
Tests AC: The Trailer Lamps Are ON Continuously
PINPOINT TEST AC: THE TRAILER LAMPS ARE ON CONTINUOUSLY
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11033
AC1
AC1-AC3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11034
AC4
Tests AD: The Trailer Battery Charging Is Inoperative
PINPOINT TEST AD: THE TRAILER BATTERY CHARGING IS INOPERATIVE
AD1-AD2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11035
AD2-AD4
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11036
AD4-AD5
Tests AE: The Trailer Electric Brakes Are Inoperative
PINPOINT TEST AE: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE
AE1-AE2
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11037
AE2-AE3
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11038
AE4-AE5
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11039
AE6
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page
11040
73III Automotive Meter
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow
Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow
Relay, Battery Charge > Page 11045
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Parking Lamp > Page 11048
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Parking Lamp
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Parking Lamp > Page 11051
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Parking Lamp > Page 11052
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Parking Lamp > Page 11053
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp
Turn Signal Lamp: Diagrams Park/Turn Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp > Page 11059
Turn Signal Lamp: Diagrams Park/Stop/Turn Lamp
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Page 11060
Turn Signal Lamp: Service and Repair
SIDE TURN SIGNAL LAMP - SIGNAL MIRROR
Removal and Installation
NOTE: Navigator shown, Expedition similar.
1. Release the two tabs and remove the mirror glass.
2. CAUTION: Take care not to break the tabs.
Slide the lamp assembly away from the vehicle, release the tabs and remove the signal mirror lamp
assembly. Separate the bulb holders from the lamp assembly.
3. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations >
Page 11064
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Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations >
Page 11065
Turn Signal Relay: Testing and Inspection
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Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations >
Page 11066
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 11070
Turn Signal Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 11071
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Multifunction Switch, Lamp Portion
Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Multifunction Switch, Lamp Portion > Page 11074
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Multifunction Switch, Lamp Portion > Page 11075
Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Multifunction Switch, Lamp Portion > Page 11076
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Multifunction Switch, Lamp Portion > Page 11077
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Page 11078
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
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Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and
Inspection > Page 11079
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left > Page 11084
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11090
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11091
Heated Glass Element Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11092
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11097
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11098
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11099
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11100
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11101
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
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11106
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11107
Heated Glass Element Relay: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11108
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 11113
View 151-1 (Engine Compartment)
The accessory delay relay is located in the central junction box, in the engine compartment, RH
side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 11114
Power Window Relay: Locations Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 11115
View 151-21 (Right Rear)
The quarter window open relay is located in the auxiliary relay box 2, behind trim panel, in loading
space, RH side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 11116
Power Window Relay: Locations Quarter Window Close Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations > Accessory Delay Relay > Page 11117
View 151-21 (Right Rear)
The quarter window close relay is located in the auxiliary relay box 2, behind trim panel, in loading
space, RH side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Quarter Window Open Relay > Page 11120
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay
Power Window Relay: Testing and Inspection Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11123
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11124
Power Window Relay: Testing and Inspection Quarter Window Close Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11125
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch
Power Window Switch: Locations Window Adjust Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 11131
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 11132
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 11133
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 11134
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 11137
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 11138
Power Window Switch: Diagrams Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 11139
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 11140
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 11141
Power Window Switch: Diagrams Power Quarter Window Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11144
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11145
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11146
Power Window Switch: Testing and Inspection Power Quarter Window Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11147
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11148
Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11149
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11150
Power Window Switch: Testing and Inspection Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11151
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 11152
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
Removal and Installation
Navigator front 1. Lift up on the center console armrest.
2. Remove the center console window control switch panel.
- Remove the pin-type retainer.
3. Disconnect the electrical connectors and remove the window control switch.
- Release the locking tabs.
Expedition front and Expedition passenger rear
NOTE: Driver side Expedition shown, all others similar.
4. Remove the window control switch panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 11153
5. Disconnect the electrical connector(s) and remove the window control switch.
- Release the locking tabs.
Navigator passenger rear 6. Remove the rear door trim panel. 7. Remove the window control
switch from the door trim panel.
All vehicles 8. To install, reverse removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Locations > Left Front
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Locations > Left Front > Page 11160
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Diagrams > Left Front
Front Door Window Motor: Diagrams Left Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Diagrams > Left Front > Page 11163
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Door Window Motor Initialization
Front Door Window Motor: Service and Repair Door Window Motor Initialization
DOOR WINDOW MOTOR INITIALIZATION
CAUTION: Make sure that no obstructions are present in the window system when carrying out this
procedure.
NOTE:
- The LF window motor is in proportional up/down mode until initialized.
- The LF window motor must be reinitialized whenever: the motor is removed from window
regulator drum housing, a new motor is installed, a new window regulator is installed, new window
glass is installed, glass top run removal or installation, or when carrying out any operation in which
grease or lubricants are applied to the window system.
- All LF window components (window glass, window regulator, window motor, and glass top run)
must be installed and tightened to specification before carrying out this procedure.
- If this procedure is only partially completed, the LF window motor will remain un-initialized and
only the proportional up/down functions will operate.
- Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire
procedure is completed.
- Step 7 requires that the master control switch (LF) be held in the UP position until the LF window
motor stalls the window glass into the upper header seal. Step 8 requires that the master control
switch (LF) be momentarily actuated to the DOWN position.
- Step 9 requires that the master control switch (LF) be held in the UP position until the LF window
motor stalls the window glass into the upper header seal and the window carries out its down-up
sequence, indicating successful completion of initialization.
- The key-in-ignition chime can cause the AUTO button to be pressed more or less than six times
due to the distraction of the chime.
1. NOTE: Steps 1 through 6 must be completed within 30 seconds. The entire procedure must be
completed within five minutes.
Start with the ignition key in the OFF position and with the LF door open.
2. Turn the ignition key to the ON position.
3. Press the front window control switch (LF) to the AUTO position six times (AUTO up or AUTO
down). 4. Turn the ignition key to the OFF position and make sure the LF door is open.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Door Window Motor Initialization > Page 11166
5. Press the front window control switch (LF) to the AUTO position six times (AUTO up or AUTO
down). 6. Turn the ignition key to the ON position and close the LF door. The LF window glass will
move down-up-down-up approximately 2-3 mm (0.1
in). This down-up-down-up movement indicates that the LF window motor has entered initialization
mode.
7. Pull and hold the front window control switch (LF) to the UP position until the window glass stalls
into the upper header seal.
8. Momentarily press the front window control switch (LF) to the DOWN position and release. The
window will carry out a one-touch down
operation until the window glass stalls at the bottom of travel stop designed into the window
regulator.
9. Pull and hold the front window control switch (LF) to the UP position. Continue to hold the switch
until after the window glass stalls into the
upper header seal and carries out the down-up movement. This down-up movement approximately
2-3 mm (0.1 in.) indicates that the LF window motor has been successfully initialized.
10. Verify correct operation of the LF window by carrying out a one-touch down, one-touch up,
proportional down, and proportional up. If the
window does not operate correctly, carefully repeat this procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Door Window Motor Initialization > Page 11167
Front Door Window Motor: Service and Repair Front Door Window Regulator Motor
FRONT DOOR WINDOW REGULATOR MOTOR
Removal and Installation
1. Remove the front door trim panel.
2. Position the front door weathershield aside.
3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator
assembly to hold the window regulator assembly
drum in place.
Remove the bolts and the front door window regulator motor. 1
Disconnect the electrical connector.
2 Remove the bolts.
4. To install, reverse the removal procedure.
- Cycle the window glass to make sure the gears engage.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component
Information > Locations > LH Side Rear
View 151-19 (Left Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component
Information > Locations > LH Side Rear > Page 11172
View 151-21 (Right Rear)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component
Information > Diagrams > LH Side Rear
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component
Information > Diagrams > LH Side Rear > Page 11175
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component
Information > Diagrams > Page 11176
Quarter Window Motor: Service and Repair
REAR QUARTER WINDOW REGULATOR MOTOR
Removal and Installation
1. Remove the D-pillar trim panel.
2. Disconnect the rear quarter window regulator motor.
- Remove the retaining clip.
3. Remove the bolts and rear quarter window regulator motor.
- Disconnect the electrical connector.
4. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Locations > Left Rear
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Locations > Left Rear > Page 11181
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Diagrams > Left
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Diagrams > Left > Page 11184
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Diagrams > Page 11185
Rear Door Window Motor: Service and Repair
REAR DOOR WINDOW REGULATOR MOTOR
Removal and Installation
1. Remove the rear door trim panel.
2. Position the rear door weathershield aside.
3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window
regulator assembly to hold the window regulator
assembly drum in place.
Remove the rear door window regulator motor. 1
Disconnect the electrical connector.
2 Remove the bolts.
4. To install, reverse the removal procedure.
- Cycle the door glass to make sure of gear engagement.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
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 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Accessory Delay Relay > Page 11190
View 151-1 (Engine Compartment)
The accessory delay relay is located in the central junction box, in the engine compartment, RH
side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Accessory Delay Relay > Page 11191
Power Window Relay: Locations Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Accessory Delay Relay > Page 11192
View 151-21 (Right Rear)
The quarter window open relay is located in the auxiliary relay box 2, behind trim panel, in loading
space, RH side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Accessory Delay Relay > Page 11193
Power Window Relay: Locations Quarter Window Close Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Accessory Delay Relay > Page 11194
View 151-21 (Right Rear)
The quarter window close relay is located in the auxiliary relay box 2, behind trim panel, in loading
space, RH side.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams >
Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams >
Quarter Window Open Relay > Page 11197
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Quarter Window Open Relay
Power Window Relay: Testing and Inspection Quarter Window Open Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Quarter Window Open Relay > Page 11200
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Quarter Window Open Relay > Page 11201
Power Window Relay: Testing and Inspection Quarter Window Close Relay
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Inspection > Quarter Window Open Relay > Page 11202
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch
Power Window Switch: Locations Window Adjust Switch
View 151-31 (Right Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 11207
View 151-30 (Left Rear Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 11208
View 151-28 (Driver Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 11209
View 151-29 (Passenger Door)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 11210
View 151-23 (Roof)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 11213
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 11214
Power Window Switch: Diagrams Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 11215
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 11216
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 11217
Power Window Switch: Diagrams Power Quarter Window Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11220
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11221
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11222
Power Window Switch: Testing and Inspection Power Quarter Window Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11223
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11224
Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11225
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11226
Power Window Switch: Testing and Inspection Window Adjust Switch
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 11227
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 11228
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
Removal and Installation
Navigator front 1. Lift up on the center console armrest.
2. Remove the center console window control switch panel.
- Remove the pin-type retainer.
3. Disconnect the electrical connectors and remove the window control switch.
- Release the locking tabs.
Expedition front and Expedition passenger rear
NOTE: Driver side Expedition shown, all others similar.
4. Remove the window control switch panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 11229
5. Disconnect the electrical connector(s) and remove the window control switch.
- Release the locking tabs.
Navigator passenger rear 6. Remove the rear door trim panel. 7. Remove the window control
switch from the door trim panel.
All vehicles 8. To install, reverse removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and
Repair > Front Door Glass Top Run
Window Frame: Service and Repair Front Door Glass Top Run
FRONT DOOR GLASS TOP RUN
Removal and Installation
1. Remove the front door window glass.
2. Remove the inside glass weatherstrip.
3. Remove the front door glass channel bolt and front door glass top run. 4. To install, reverse the
removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and
Repair > Front Door Glass Top Run > Page 11234
Window Frame: Service and Repair Rear Door Glass Top Run
REAR DOOR GLASS TOP RUN
Removal and Installation
1. Lower the rear door window glass. 2. Remove the rear door trim panel.
3. Remove the inside glass weatherstrip.
4. Remove the rear door glass channel bolts. 5. Remove the rear door glass top run. 6. To install,
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched
Front Door Window Glass: Customer Interest Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 11244
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 11245
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 11246
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 11247
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May >
07 > Body - Front Door Window Scratched
Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May >
07 > Body - Front Door Window Scratched > Page 11253
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May >
07 > Body - Front Door Window Scratched > Page 11254
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May >
07 > Body - Front Door Window Scratched > Page 11255
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May >
07 > Body - Front Door Window Scratched > Page 11256
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11257
Front Door Window Glass: By Symptom
Technical Service Bulletin # 07-10-5 Date: 070528
Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11258
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11259
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11260
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11261
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Technical Service Bulletin # 07-10-5 Date: 070528
Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11262
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11263
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11264
The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And
Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass:
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11265
Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Page 11266
Front Door Window Glass: Service and Repair
FRONT DOOR WINDOW GLASS
Removal and Installation
All vehicles 1. Remove the front door trim panel.
2. Remove the front door weathershield.
Expedition
3. NOTE: Driver side shown, passenger side similar.
Connect the window control switch.
All vehicles 4. Lower the window glass to access the two window glass to regulator bolts.
5. Remove the inside glass weatherstrip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Page 11267
6. Remove the front door glass channel bolt and position aside the channel.
7. Remove the window glass to regulator bolts and front door window glass. 8. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair
Liftgate Window Glass: Service and Repair
LIFTGATE WINDOW GLASS
Removal and Installation
1. Remove the rear window wiper motor.
2. Disconnect the rear window defrost electrical connectors.
3. CAUTION:
- The liftgate glass must be supported when removing and installing the liftgate assist cylinders.
- Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can occur
Disconnect the two liftgate glass assist cylinders. 1
Insert a screwdriver blade under the socket clip and lift.
2 Gently pull the socket off the ball stud.
4. Remove the liftgate glass hinge bolts and remove the glass.
- Apply High Strength Threadlocker to the liftgate glass hinge bolts during installation.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair
Quarter Window Glass: Service and Repair
REAR QUARTER WINDOW GLASS
Removal
All vehicles 1. Remove the rear quarter trim panel.
2. CAUTION: To prevent damage to the coat hanger retainer, use a 3/16-inch flat-blade
screwdriver for this step.
Remove the front and rear coat hooks and lower the headliner over the rear quarter window glass.
Open the access cover.
- Insert a screwdriver into the coat hook slot and turn the screwdriver 90 degrees so that it engages
in the plastic component slot. This will spread the steal attachment clip wings to allow the plastic
component to disengage.
Vehicles with power vent window
3. Remove the bolts and rear quarter window regulator motor.
- Disconnect the electrical connector.
4. Disconnect the rear quarter window regulator.
All vehicles
5. Disconnect the audio antenna.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 11274
6. If equipped, remove the air duct.
- Remove the pin-type retainer.
7. CAUTION: Have an assistant hold the rear quarter window glass.
Remove the rear quarter window glass. 1
Remove the nuts.
2 Remove the rear quarter window glass.
8. Remove the excess foam butyl from the window opening.
Installation
All vehicles 1. Apply 8 mm (0.32 in) Foam Butyl of equivalent meeting Ford specification
WSB-M4GB45-A to the rear quarter window glass frame.
- Start at the bottom middle and work around the frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 11275
2. Install the rear quarter window glass.
1 Position the rear quarter window glass.
2 Install the rear quarter window glass nuts.
3. If equipped, install the air duct.
- Install the pin-type retainer.
4. Connect the audio antenna.
Vehicles with power vent windows
5. Install the rear quarter window regulator.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 11276
6. Install the bolts and rear quarter window regulator motor.
- Connect the electrical connector.
All vehicles 7. Position the headliner and install the coat hooks. 8. Install the rear quarter trim
panel.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Rear Door Window Glass
Rear Door Window Glass: Service and Repair Rear Door Window Glass
REAR DOOR WINDOW GLASS
Removal and Installation
1. Remove the rear door trim panel.
2. Position back the rear door weathershield. 3. Connect the window control switch. 4. Lower the
window glass to access the two window glass to regulator bolts.
5. Remove the inside glass weatherstrip.
6. Remove the rear door glass channel bolts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Rear Door Window Glass > Page 11281
7. Remove the window glass to regulator bolts and rear door window glass. 8. To install, reverse
the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Rear Door Window Glass > Page 11282
Rear Door Window Glass: Service and Repair Stationary
REAR DOOR WINDOW GLASS - STATIONARY
Removal and Installation
1. Remove the rear door window glass.
2. Remove the rear door exterior glass moulding. 3. Remove the rear door glass top run.
4. Remove the rear door stationary glass screw.
5. Remove the stationary rear door glass. 6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair
Front Door Window Regulator: Service and Repair
FRONT DOOR WINDOW REGULATOR
Removal and Installation
All vehicles 1. Remove the front door trim panel.
2. Remove the screws and the front door speaker.
- Disconnect the electrical connector.
3. Remove the front door weathershield.
Expedition
4. NOTE: Driver side shown, passenger side similar.
Connect the window control switch.
All vehicles 5. Lower the window glass to access the two window glass-to-regulator bolts.
Expedition
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 11287
6. NOTE: Driver side shown, passenger side similar.
Disconnect the window control switch.
All vehicles
7. Remove the window glass-to-regulator bolts and front door window glass.
8. NOTE: Secure the front window glass in the full up position.
Secure the front window glass with tape to the front door frame.
9. Position the interior door handle aside.
1 Remove the cable conduit fitting from the carrier assembly.
2 Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of
the bracket.
3 Remove the cable from the door handle.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 11288
10. Release the crash sensor harness pin-type retainers.
11. Position the front door window regulator harness aside.
1 Disconnect the electrical connectors.
2 Release the pin-type retainers.
12. Remove the front window regulator.
1 Loosen the two hanger bolts.
2 Remove the front window regulator bolts and front top run channel bolt.
13. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair
Rear Door Window Regulator: Service and Repair
REAR DOOR WINDOW REGULATOR
Removal and Installation
1. Remove the rear door trim panel.
2. Remove the rear door speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
3. Remove the rear door weathershield. 4. Connect the window control switch. 5. Lower the
window glass to access the two window glass-to-regulator bolts. 6. Disconnect the window control
switch.
7. Remove the window glass-to-regulator bolts and rear door window glass.
8. NOTE: Secure the rear window glass in the full up position.
Secure the rear window glass with tape to the front door frame.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Page 11292
9. Disconnect the rear door window regulator electrical connectors.
10. Position the interior door handle aside.
- Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of
the bracket.
11. Remove the rear door window regulator assembly.
- Remove the bolts.
12. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched
Window Seal: Customer Interest Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 11301
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 11302
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 11303
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 11304
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 06-13-4 > Jul > 06 > Body - Wind Noise From Around Outside Mirrors
Window Seal: Customer Interest Body - Wind Noise From Around Outside Mirrors
TSB 06-13-4
07/10/06
WIND / WHISTLE NOISE AROUND OUTSIDE MIRRORS
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
ISSUE Some 2003-2005 Expedition / Navigator vehicles may exhibit wind / whistle noise around
the outside mirrors at speeds above 40 MPH (64 Km/h).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Inspect the foam strip located on the glass run where it contacts the front portion of the window
flange. This foam can sometimes be rolled over into the channel of the glass run so that the foam is
caught between the window flange and the glass run channel (Figure 1). In this case the foam
should be pulled from the channel and routed further outboard on the glass run to ensure it does
not get trapped again during installation.
a. To inspect for this condition the interior door trim panel and the outside door belt moulding need
to be removed, Workshop Manual (WSM), Section 501. Once the door trim and belt moulding has
been removed, simply pulling off the front glass run from the window channel to view the position of
the foam strip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 06-13-4 > Jul > 06 > Body - Wind Noise From Around Outside Mirrors >
Page 11309
2. On vehicles built before 11/19/2004, it may be necessary to place a small strip of sticky backed
foam, or plastic (which can be found in the Rotunda 164-R4900 Squeak and Rattle Repair Kit /
Cavity number 164-R4903) in the front portion of the horizontal cutline of the mirror (Figure 2 and
3). This will redirect the airflow in this location and eliminate the wind noise.
3. If the noise is still present, continue with normal diagnostics using WSM, Section 100-0.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061304A 2003-2005 0.5 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding One Door (Do Not Use With 23943A)
061304B 2003-2005 0.9 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding Both Doors (Do Not Use With 23943A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17682 12
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched
Window Seal: All Technical Service Bulletins Body - Front Door Window Scratched
TSB 07-10-5
05/28/07
FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN
WARPED OUTER WINDOW MOLDING
FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty
LINCOLN: 2007 Navigator
This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and
parts information.
ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator
vehicles may exhibit outer window molding weather strip assembly warping around the lower front
window channel. The condition may be described as a warped or loose outer window molding.
There may be a pucker or gap between the window beltline molding weather strip assembly and
the window glass. This may result in dirt and debris collecting between the molding and the glass,
and therefore scratching the side-window glass.
ACTION Use the Service Procedure to replace the outer window molding and adjust the molding
flange.
SERVICE PROCEDURE
1. Lower the side door window completely.
2. Remove the outside mirror.
3. Remove the outer window molding weather strip assembly by lifting it up away from the flange
(Figure 1).
4. Raise the side door glass completely.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched >
Page 11315
5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the
window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for
F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator.
6. Lower glass completely.
7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange
more than 3/4" (19 mm) away from the glass.
8. Install a new lower window molding weather strip assembly.
9. Reinstall mirror.
10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual,
Section 501-11.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched >
Page 11316
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071005A 2005-2008 F-Super Duty, 0.5 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005B 2005-2008 F-Super Duty, 0.9 Hr.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B,
23943A14, 18808AF, 17682B)
071005C 2005-2008 F-Super Duty, 0.7 Hr.
2005 Excursion: Replace The Window Beltline
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched >
Page 11317
Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass:
One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF,
17682B)
071005D 2005-2008 F-Super Duty, 1.3 Hrs.
2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust
Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B,
17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B)
071005E 2003-2007 Expedition, 0.6 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
07100SF 2003-2007 Expedition, 1.1 Hrs.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
071005G 2003-2007 Expedition, 0.9 Hr.
2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust
Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C,
21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B)
071005H 2003-2007 Expedition, 1.7 Hrs.
2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door
Molding Flange And Replace Window Glass: Both Front Doors (Do Not
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 07-10-5 > May > 07 > Body - Front Door Window Scratched >
Page 11318
Use With 17682C, 21452A, 23943A, 23943AB,
23943A14, 18808AF, 17682B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2521452 07
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 06-13-4 > Jul > 06 > Body - Wind Noise From Around Outside
Mirrors
Window Seal: All Technical Service Bulletins Body - Wind Noise From Around Outside Mirrors
TSB 06-13-4
07/10/06
WIND / WHISTLE NOISE AROUND OUTSIDE MIRRORS
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
ISSUE Some 2003-2005 Expedition / Navigator vehicles may exhibit wind / whistle noise around
the outside mirrors at speeds above 40 MPH (64 Km/h).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Inspect the foam strip located on the glass run where it contacts the front portion of the window
flange. This foam can sometimes be rolled over into the channel of the glass run so that the foam is
caught between the window flange and the glass run channel (Figure 1). In this case the foam
should be pulled from the channel and routed further outboard on the glass run to ensure it does
not get trapped again during installation.
a. To inspect for this condition the interior door trim panel and the outside door belt moulding need
to be removed, Workshop Manual (WSM), Section 501. Once the door trim and belt moulding has
been removed, simply pulling off the front glass run from the window channel to view the position of
the foam strip.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 06-13-4 > Jul > 06 > Body - Wind Noise From Around Outside
Mirrors > Page 11323
2. On vehicles built before 11/19/2004, it may be necessary to place a small strip of sticky backed
foam, or plastic (which can be found in the Rotunda 164-R4900 Squeak and Rattle Repair Kit /
Cavity number 164-R4903) in the front portion of the horizontal cutline of the mirror (Figure 2 and
3). This will redirect the airflow in this location and eliminate the wind noise.
3. If the noise is still present, continue with normal diagnostics using WSM, Section 100-0.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061304A 2003-2005 0.5 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding One Door (Do Not Use With 23943A)
061304B 2003-2005 0.9 Hr.
Expedition/Navigator: Inspect And Adjust Foam Strip, And Install Sticky Back Foam Strip Onto The
Mirror, Includes Time To Remove And Install Front Interior Door Trim Panel And Interior Belt
Molding Both Doors (Do Not Use With 23943A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17682 12
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal
Windshield: Service and Repair Windshield Reseal
WINDSHIELD RESEAL
1. Remove the cowl grille.
2. Remove the A-pillar trim panels.
- Remove the bolt covers and bolts.
3. If equipped, remove the overhead console. 4. If equipped, remove the roof opening panel trim. 5.
Remove the interior rear view mirror.
6. Remove the sun visors.
1 Remove the four screws.
2 Remove the two sun visor and visor arm clips. If equipped, disconnect the electrical connectors.
7. Partially lower the front portion of the headliner near the windshield upper opening and block
with a suitable material. 8. Clean the edge formed by the existing urethane and the glass on the
inside at the top and sides, and outside on the bottom of the windshield with an
alcohol free cleaner.
9. Cut the urethane applicator tip to specification.
10. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane
with less effort and a continuous bead.
Apply a bead of Urethane Adhesive Essex 400-HV to the cleaned area.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11328
11. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous
bead.
Backfill the urethane application and clean the excess.
12. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or
water leaks.
After the urethane has cured, check the windshield seal for air or water leaks through the urethane
adhesive bead and add urethane adhesive as necessary.
13. Install the headliner.
14. Install the sun visors.
1 Position the sun visors.
2 Install the four screws. If equipped, connect the electrical connectors.
15. Install the interior rear view mirror. 16. If equipped, install the roof opening panel trim. 17. If
equipped, install the overhead console. 18. Install the A-pillar trim panels.
- Install the bolts and covers.
19. Install the cowl grille. 20. Clean the interior and exterior of the windshield glass with an alcohol
free cleaner.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11329
Windshield: Service and Repair Windshield Glass
WINDSHIELD GLASS
Special Tool(s)
Special 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.
2. Remove the A-pillar trim panels.
- Remove the bolt covers and bolts.
3. If equipped, remove the overhead console. 4. Remove the interior rear view mirror.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11330
5. Remove the sun visors.
1 Remove the four screws
2 Remove the two sun visor and visor arm clips If equipped, disconnect the electrical connectors.
6. Lower the front portion of the headliner.
7. Remove the windshield side mouldings.
- Pull out starting at the top corner.
8. Remove the upper windshield weatherstrip.
- Pull out starting at the corner.
9. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops
when cutting the urethane.
10. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11331
11. CAUTION: Care must be taken to avoid scratching the pinchweld.
NOTE: Lubricate the urethane adhesive with water to aid the special tool while cutting.
Using the special tool, cut the urethane adhesive from the windshield glass. Insert the blade into the urethane at the top middle of the glass and work toward the top corners.
- Insert the blade at the top corners and work down each side of the glass toward the bottom.
12. CAUTION: Pump special tool 164-R2459 or equivalent slowly as cowl adhesive is cut to avoid
breaking glass.
Using the special tool, distance the windshield from the body.
13. NOTE: Removing the windshield glass requires an assistant.
Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
14. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.
Installation
CAUTION:
- Do not drive the vehicle after installing windshield glass until the urethane adhesive has cured.
Inadequate curing of the urethane adhesive adversely affects the strength of the urethane adhesive
bond.
- If using Urethane Adhesive Essex 400, the curing time at temperatures above 13°C (55°F) and
relative humidity above 50% is 12-24 hours. Curing time decreases at higher temperatures and/or
lower humidities.
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
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11332
to bottom. Make the alignment marks with tape or non-staining grease pencil on both the glass and
the vehicle body.
2. CAUTION: Care must be taken to avoid scratching the pinch weld.
Trim the remaining urethane adhesive on the pinch weld to within specification. The old urethane surface should be smooth and free of cuts and contamination.
3. Use the wool applicator to apply Urethane Metal Primer Essex U-413, meeting Ford specification
WSB-M2G234-C to any exposed metal on the
pinch weld. Allow six to ten minutes to dry.
4. If reinstalling the original windshield, remove excess urethane adhesive from the windshield
glass. 5. 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.
6. CAUTION: Wipe off Urethane Glass Prep Essex U-401 immediately after each application
because it flash dries.
NOTE: Apply with deliberate strokes, making sure not to overlap applied area.
Apply Urethane Glass Prep Essex U-401 or equivalent meeting Ford specification WSB-M5B280-C
twice around the glass surface to be prepped.
7. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M2G314-B to the
same area that was in the previous step. Allow five
minutes to dry.
8. Install the upper windshield weatherstrip.
9. Cut the urethane applicator tip to specification.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11333
10. CAUTION:
- Do not drive the vehicle after installing windshield glass until the urethane adhesive has cured.
Inadequate curing of the urethane adhesive adversely affects the strength of the urethane adhesive
bond.
- If using Urethane Adhesive Essex 400-HV, the curing time at temperatures above 13°C (55°F)
and relative humidity above 50% is 12-24 hours. Curing time decreases at higher temperatures
and/or lower humidities.
Apply a bead of Urethane Adhesive Essex 400-HV meeting Ford specification WSB-M2G316-B to
the pinch weld just outside the foam butyl dam over the top of the existing urethane bed.
11. CAUTION: Open the windows to prevent the windshield glass from being pushed out by air
pressure if a door is closed.
Using the alignment marks, install the windshield glass.
12. Install the windshield side mouldings.
NOTE: Be sure the moldings seat completely.
13. Install the headliner. 14. Install the interior rear view mirror. 15. Install the overhead console.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Reseal > Page 11334
16. Install the A-pillar trim panels.
- Install the bolts and covers.
17. Install the sun visors.
1 Position the sun visors.
2 Install the four screws. If equipped, connect the electrical connectors.
18. Install the cowl grille. 19. Run the blower motor on defrost HIGH to check for glass that may
have fallen into the defroster vents.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 11340
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11344
Windshield Washer Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11345
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11346
Windshield Washer Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11347
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11348
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11349
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11350
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Blade Heater Switch > Component Information > Locations
View 151-33 (Climate Control System)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Blade Heater Switch > Component Information > Locations > Page 11354
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11358
Wiper Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11359
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11360
Wiper Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11361
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11362
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 11366
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations
View 151-1 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Page 11370
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair
Windshield Washer Pump: Service and Repair
WINDSHIELD WASHER PUMP AND RESERVOIR
Removal and Installation
1. Disconnect the electrical connectors.
2. Remove the windshield washer reservoir screws.
3. NOTE: Windshield washer fluid should be collected in a container after the windshield washer
hoses are disconnected.
Disconnect the windshield washer hoses.
4. Remove the windshield washer reservoir.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair > Page 11374
5. Remove the windshield washer pump if necessary.
6. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer
reservoir.
To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer concentrate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair
Windshield Washer Reservoir: Service and Repair
WINDSHIELD WASHER PUMP AND RESERVOIR
Removal and Installation
1. Disconnect the electrical connectors.
2. Remove the windshield washer reservoir screws.
3. NOTE: Windshield washer fluid should be collected in a container after the windshield washer
hoses are disconnected.
Disconnect the windshield washer hoses.
4. Remove the windshield washer reservoir.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 11378
5. Remove the windshield washer pump if necessary.
6. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer
reservoir.
To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer concentrate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11382
Windshield Washer Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11383
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11384
Windshield Washer Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11385
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11386
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11387
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
Removal and Installation
1. Remove the steering wheel.
2. NOTE: Lower tilt release handle to access the second screw.
Remove the lower steering column shroud. ^
Remove the screws.
3. NOTE: The screw is located behind the multifunction switch.
Remove the screw and the upper steering column shroud.
4. Remove the bolt, push the release and raise the switch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11388
5. NOTE: A small screwdriver will be required to depress the connector release tab on connector
number 2.
Remove the multifunction switch. ^
Disconnect the connectors in the sequence shown.
^ Remove the switch.
6. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield
Wiper Blade and Pivot Arm Adjustment
Wiper Arm: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment
WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT
1. Cycle and park the windshield wipers.
2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) bottom
of the windshield glass and between the outer tip
of the (2) LH windshield wiper blade and the (3) bottom of the windshield glass are within
specifications.
3. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to
specification.
1 Lift the pivot arm nut cover.
2 Remove the nut.
4. Tighten the windshield wiper pivot arm nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield
Wiper Blade and Pivot Arm Adjustment > Page 11393
Wiper Arm: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment
REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT
1. Cycle and park the rear window wiper pivot arm and blade.
2. Check the rear window wiper park measurement. If not within specification the rear window
wiper pivot arm will need to be removed.
3. CAUTION: Use a shop towel or similar device to protect the vehicle finish when carrying out the
procedure.
Remove the rear window wiper pivot arm. 1
Lift the pivot arm nut cover.
2 Remove the nut.
4. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch on and allow the motor to operate for at least one cycle. Turn
the rear window wiper switch to OFF.
5. Install the rear window wiper pivot arm onto the rear window wiper motor shaft.
1 Position the wiper pivot arm within specification.
2 Tighten the nut.
3 Install the cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Windshield Wiper
Wiper Arm: Service and Repair Wiper Pivot Arm - Windshield Wiper
WIPER PIVOT ARM - WINDSHIELD WIPER
Removal
NOTE: The windshield wiper pivot arms must in the highest position to remove them.
1. Turn the ignition switch to the ON position. 2. Turn the windshield wiper on. 3. Stop the
windshield wiper pivot arms at the highest position by turning the ignition switch OFF.
4. Remove the windshield wiper pivot arm.
1 Lift the pivot arm nut cover.
2 Remove the nut.
Installation
1. To install, reverse the removal procedure.
- Adjust the windshield wiper pivot arms.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Windshield Wiper > Page 11396
Wiper Arm: Service and Repair Wiper Pivot Arm - Rear
WIPER PIVOT ARM - REAR
Removal
1. CAUTION: Use a shop towel or similar device to protect the vehicle finish when carrying out the
procedure.
Remove the rear window wiper pivot arm. 1
Lift the pivot arm nut cover.
2 Remove the nut.
Installation
1. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch on and allow the motor to operate for at least one cycle. Turn
the rear window wiper switch to OFF.
2. Install the rear window wiper pivot arm onto the rear window wiper motor shaft.
1 Position the wiper pivot arm within specification.
2 Tighten the nut.
3 Install the cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments >
Windshield Wiper Blade and Pivot Arm Adjustment
Wiper Blade: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment
WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT
1. Cycle and park the windshield wipers.
2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) bottom
of the windshield glass and between the outer tip
of the (2) LH windshield wiper blade and the (3) bottom of the windshield glass are within
specifications.
3. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to
specification.
1 Lift the pivot arm nut cover.
2 Remove the nut.
4. Tighten the windshield wiper pivot arm nuts.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments >
Windshield Wiper Blade and Pivot Arm Adjustment > Page 11401
Wiper Blade: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment
REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT
1. Cycle and park the rear window wiper pivot arm and blade.
2. Check the rear window wiper park measurement. If not within specification the rear window
wiper pivot arm will need to be removed.
3. CAUTION: Use a shop towel or similar device to protect the vehicle finish when carrying out the
procedure.
Remove the rear window wiper pivot arm. 1
Lift the pivot arm nut cover.
2 Remove the nut.
4. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch on and allow the motor to operate for at least one cycle. Turn
the rear window wiper switch to OFF.
5. Install the rear window wiper pivot arm onto the rear window wiper motor shaft.
1 Position the wiper pivot arm within specification.
2 Tighten the nut.
3 Install the cover.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations
View 151-33 (Climate Control System)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations
> Page 11405
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-19-8 > Oct > 05 > Wipers/Washers - Rear Window Wiper Inoperative
Wiper Motor: Customer Interest Wipers/Washers - Rear Window Wiper Inoperative
TSB 05-19-8
10/03/05
REAR WINDOW WIPER INOPERATIVE
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 4/1/2005 may exhibit an
inoperative rear window wiper, where the rear wiper motor can be heard operating, but the rear
wiper arm is not moving. This condition may be due to the rear window wiper motor mounting
surface not being perpendicular to the liftgate door, resulting in the rear wiper arm pivot
disengaging from the wiper motor.
ACTION Add a shim between the wiper motor bracket and wiper motor mounting surface at the two
(2) bracket holes closest to the front of the vehicle.
SERVICE PROCEDURE
1. Access the rear wiper motor bracket by removing the liftgate trim panel per Workshop Manual
Section 501-05.
2. Remove the two (2) wiper motor bracket bolts closest to the front of vehicle (Figure 1) and
loosen the other two (2) bracket bolts. Add a 0.04-0.08(1-2 mm) thick stainless steel washer
between the wiper motor bracket and mounting surface, to raise the rear of the wiper motor
assembly.
3. Reinstall bolts and torque to 97 lb-in (11 N.m).
4. Verify that the pivot shaft pin is aligned with the hole in the motor disc. If not, add or remove
washers as needed to obtain alignment.
5. Install liftgate trim panel per Workshop Manual Section 501-05.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051908A 2003-2005 0.5 Hr.
Expedition/Navigator: Install Shim Between The Wiper Motor Bracket And Wiper
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest: > 05-19-8 > Oct > 05 > Wipers/Washers - Rear Window Wiper Inoperative > Page 11414
Motor Mounting Surface
DEALER CODING
CONDITION
BASIC PART NO. CODE
17508 07
OASIS CODES: 202000
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-19-8 > Oct > 05 > Wipers/Washers - Rear Window Wiper Inoperative
Wiper Motor: All Technical Service Bulletins Wipers/Washers - Rear Window Wiper Inoperative
TSB 05-19-8
10/03/05
REAR WINDOW WIPER INOPERATIVE
FORD: 2003-2005 Expedition
LINCOLN: 2003-2005 Navigator
ISSUE Some 2003-2005 Expedition/Navigator vehicles built before 4/1/2005 may exhibit an
inoperative rear window wiper, where the rear wiper motor can be heard operating, but the rear
wiper arm is not moving. This condition may be due to the rear window wiper motor mounting
surface not being perpendicular to the liftgate door, resulting in the rear wiper arm pivot
disengaging from the wiper motor.
ACTION Add a shim between the wiper motor bracket and wiper motor mounting surface at the two
(2) bracket holes closest to the front of the vehicle.
SERVICE PROCEDURE
1. Access the rear wiper motor bracket by removing the liftgate trim panel per Workshop Manual
Section 501-05.
2. Remove the two (2) wiper motor bracket bolts closest to the front of vehicle (Figure 1) and
loosen the other two (2) bracket bolts. Add a 0.04-0.08(1-2 mm) thick stainless steel washer
between the wiper motor bracket and mounting surface, to raise the rear of the wiper motor
assembly.
3. Reinstall bolts and torque to 97 lb-in (11 N.m).
4. Verify that the pivot shaft pin is aligned with the hole in the motor disc. If not, add or remove
washers as needed to obtain alignment.
5. Install liftgate trim panel per Workshop Manual Section 501-05.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051908A 2003-2005 0.5 Hr.
Expedition/Navigator: Install Shim Between The Wiper Motor Bracket And Wiper
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 05-19-8 > Oct > 05 > Wipers/Washers - Rear Window Wiper Inoperative >
Page 11420
Motor Mounting Surface
DEALER CODING
CONDITION
BASIC PART NO. CODE
17508 07
OASIS CODES: 202000
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Motor: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative
Wiper Pivot: All Technical Service Bulletins Wipers/Washers - Rear Wiper is Inoperative
TSB 07-10-13
05/28/07
REAR WIPER INOPERATIVE
FORD: 2003-2007 Expedition
LINCOLN: 2003-2007 Navigator
This article supersedes TSB 06-22-10 to update the vehicle model years.
ISSUE Some 2003-2007 Expedition and Navigator vehicles, the rear wiper may not return to park
position. In this case, the rear wiper system will attempt to park periodically causing a battery
drain.This concern may be caused by corrosion on the wiper pivot shaft assembly.
ACTION Use the following Service Procedure to identify and replace the rear window striker/wiper
pivot shaft assembly.
SERVICE PROCEDURE
1. Disengage rear wiper mechanism by partially opening the rear liftgate glass. (Figure 1)
2. Access the rear wiper arm attaching nut. (Figure 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Motor: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative > Page 11426
3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm
throughout the entire travel of the wiper arm. (Figure 3)
a. This must be done while the glass is open so that the wiper mechanism is disengaged from the
motor drive plate.
b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm.
c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either
direction.
(1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot
shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and
Installation. (Figure 4)
(2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal
Workshop Manual diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Motor: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative > Page 11427
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071013A 2003-2007 0.7 Hr.
Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To
Verify Concern (Do Not Use With 40860B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17C426 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Motor: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative > Page 11433
3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm
throughout the entire travel of the wiper arm. (Figure 3)
a. This must be done while the glass is open so that the wiper mechanism is disengaged from the
motor drive plate.
b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm.
c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either
direction.
(1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot
shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and
Installation. (Figure 4)
(2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal
Workshop Manual diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiper Motor: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative > Page 11434
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071013A 2003-2007 0.7 Hr.
Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To
Verify Concern (Do Not Use With 40860B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17C426 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield
Wiper Motor
View 151-2 (Engine Compartment)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield
Wiper Motor > Page 11437
View 151-32 (Liftgate)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector
Views
Wiper Motor: Connector Views
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection >
Windshield Wiper Motor
Wiper Motor: Testing and Inspection Windshield Wiper Motor
WINDSHIELD WIPER MOTOR
CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper
operations. Failure to follow this caution may result in damage to the motor magnets and will make
the windshield wiper motor inoperative. Rough handling of new windshield wiper motors may also
damage the motor magnets.
NOTE:
- Windshield wiper motor component test is carried out to determine if windshield wiper motor and
module are functional and not in for default mode. Refer to Principles of Operation. See: Testing
and Inspection/Initial Inspection and Diagnostic Overview/Principles of Operation
- Battery voltage must remain within 10 to 15 VDC to carry out test and keep windshield wiper
motor from entering its software safe mode.
- When connecting the power and ground test leads to the windshield wiper motor terminals, care
must be taken to not short terminals between power and ground, as well as making sure the logic
ground, pin 3, is always securely connected to prevent permanent windshield wiper motor module
damage.
If the windshield wiper motor does not pass any of the following tests, install a new windshield
wiper motor.
Use SABRE Premium Battery and Electrical System Tester 010-00736 or equivalent to test the
windshield wiper motor.
To test the windshield wiper motor, remove the windshield wiper mounting arm and pivot shaft from
the windshield wiper motor. Refer to Windshield Wiper Blade and Pivot Arm Adjustment. See:
Wiper Blade/Adjustments
Disconnect the wiper motor. Connect the (1) green lead from the (2) SABRE to the battery negative
(-) post. Connect the red lead (3) from the SABRE to the wiper motor (4) component side connector
ground and logic ground pins 6 and 3 (3). Connect battery positive cable (5) to windshield wiper
motor (4) component side connector battery and logic positive pins 5 and 8 (5).
Low Speed
Test the low speed mode by connecting a separate set of test leads from battery ground (-) post to
windshield wiper motor (4) component side pins 9 and 10 (6). When these pins are grounded, the
windshield wiper motor operation should now be in low speed mode.
High Speed
Test the high speed mode by connecting a separate set of test leads from battery ground (-) post to
windshield wiper motor (4) component side pins 1, 9, and 10 (7). When these pins are grounded,
the windshield wiper motor operation should now be in high speed mode.
Washer Pump Relay (Integral)
Test the windshield wiper motor internal washer relay function by measuring the voltage between
windshield wiper motor (4) component side pin 7 (8), and ground while grounding the windshield
wiper motor (4) component side pin 12 (9). When wash command input pin 12 is grounded,
measured
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection >
Windshield Wiper Motor > Page 11442
voltage should read 10 volts or greater.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection >
Windshield Wiper Motor > Page 11443
Wiper Motor: Testing and Inspection Rear Window Wiper Motor
REAR WINDOW WIPER MOTOR
CAUTION: Do not handle the rear window wiper motor abusively when diagnosing the wiper
operations. Failure to follow this caution may result in damage to the motor magnets and will make
the rear window wiper motor inoperative. Rough handling of new rear window wiper motors may
also damage the motor magnets.
NOTE:
- The Rear window wiper motor component test is carried out to determine if wiper motor and
module are functional.
- Battery voltage must remain within 10 to 15 VDC to carry out test and keep wiper motor from
entering its software safe mode.
- When connecting the power and ground test leads to the rear wiper motor terminals, care must be
taken to not short terminals between power and ground, as well as insuring the logic ground, pin 3,
is always securely connected to prevent permanent rear window wiper motor module damage.
If the rear window wiper motor does not pass any of the following tests, install a new rear window
wiper motor.
Use the SABRE Premium Battery and Electrical System Tester 010-00736 or equivalent to test the
rear window wiper motor.
Disconnect the rear window wiper motor. Connect the (1) green lead from the (2) SABRE to the
battery negative (-) post. Connect the red lead (3) from the SABRE to the wiper motor (4)
component side connector ground pins 1 and 2 (3). Connect battery positive cable (5) to wiper
motor (4) component side connector battery and logic positive pins 3 and 4 (5).
On Mode
Test the on mode by connecting a separate set of test leads from battery ground (-) post to
windshield wiper motor (4) component side pins 6 and 7 (6). When these pins are grounded, the
rear window wiper motor operation should now be in on mode.
Washer Pump Relay (Integral)
Test the rear window wiper motor internal washer relay function by measuring the voltage between
wiper motor (4) component side pin 5 (7), and ground. When wash command input pin 6 (7) is
grounded, measured voltage should read 10 volts or greater.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor
Wiper Motor: Service and Repair Windshield Wiper Motor
WINDSHIELD WIPER MOTOR
Removal and Installation
1. Remove the mounting arm and pivot shaft.
2. NOTE: Mark the position of the windshield wiper motor crank before it is disconnected.
Disconnect the windshield wiper motor crank. Remove the bolt.
3. Remove the bolts and the windshield wiper motor.
4. NOTE: The windshield wiper motor crank must be set to the same location for the windshield
wiper mounting arm and pivot shaft to be installed
properly. Refer to component test. See: Testing and Inspection/Component Tests and General
Diagnostics/Windshield Wiper Motor
To install reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 11446
Wiper Motor: Service and Repair Rear Window Wiper Motor
REAR WINDOW WIPER MOTOR
Removal
1. Remove the rear wiper pivot arm.
2. Remove the dust boot cover.
3. Remove the rear window wiper pivot shaft nut and handle. 4. Open the liftgate glass.
5. Remove the nuts and the rear window striker and wiper pivot shaft assembly. 6. Remove the
liftgate trim panel. 7. Close the liftgate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 11447
8. If installing a new rear wiper motor, remove the liftgate window glass latch.
1 Disconnect the electrical connector.
2 Remove the bolts.
9. Remove the rear window wiper motor.
1 Disconnect the electrical connector.
2 Remove the bolts.
Installation
1. If installing a new rear wiper motor, install the liftgate window glass latch.
2. NOTE: An audible click should be heard as the striker engages the latch.
Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft
pin should be aligned with the hole in the motor
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 11448
disc.
3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is
provided with the motor assembly.
1 Make sure the alignment tool fits over the motor disc and striker assembly.
2 Make sure the alignment tool clips are securely engaged.
4. Install the rear wiper motor.
1 Tighten the bolts.
2 Connect the electrical connectors.
5. Carefully close the liftgate glass.
6. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly
nuts. 7. Close the liftgate.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 11449
8. Install the rear window wiper pivot shaft nut and handle.
9. Install the dust boot cover.
10. Install the rear wiper pivot arm. 11. Open the liftgate.
12. Remove the rear window wiper motor aligning tool. 13. Open the liftgate glass. 14. Install the
liftgate trim panel. 15. Test the liftgate and liftgate glass for normal operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and
Repair > Wiper Mounting Arm and Pivot Shaft - Windshield
Wiper Motor Linkage: Service and Repair Wiper Mounting Arm and Pivot Shaft - Windshield
WIPER MOUNTING ARM AND PIVOT SHAFT - WINDSHIELD
Removal and Installation
1. Remove the cowl grille panel. 2. Disconnect and position the hood light harness aside. 3.
Remove the hood struts.
- Using a suitable tool support the hood.
4. Remove the mounting arm and pivot shaft assembly.
1 Disconnect the electrical connector and position the wiring harness aside.
2 Remove the bolts.
5. To install, reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and
Repair > Wiper Mounting Arm and Pivot Shaft - Windshield > Page 11454
Wiper Motor Linkage: Service and Repair Wiper Mounting Arm and Pivot Shaft - Rear
WIPER MOUNTING ARM AND PIVOT SHAFT - REAR
Removal and Installation
1. Remove the rear wiper pivot arm. 2. Remove the dust boot cover.
3. Remove the nut and the rear window glass handle.
4. Remove the nuts and the rear window wiper striker and wiper pivot shaft assembly. 5. To install
reverse the removal procedure.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative
Wiper Pivot: Customer Interest Wipers/Washers - Rear Wiper is Inoperative
TSB 07-10-13
05/28/07
REAR WIPER INOPERATIVE
FORD: 2003-2007 Expedition
LINCOLN: 2003-2007 Navigator
This article supersedes TSB 06-22-10 to update the vehicle model years.
ISSUE Some 2003-2007 Expedition and Navigator vehicles, the rear wiper may not return to park
position. In this case, the rear wiper system will attempt to park periodically causing a battery
drain.This concern may be caused by corrosion on the wiper pivot shaft assembly.
ACTION Use the following Service Procedure to identify and replace the rear window striker/wiper
pivot shaft assembly.
SERVICE PROCEDURE
1. Disengage rear wiper mechanism by partially opening the rear liftgate glass. (Figure 1)
2. Access the rear wiper arm attaching nut. (Figure 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page
11463
3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm
throughout the entire travel of the wiper arm. (Figure 3)
a. This must be done while the glass is open so that the wiper mechanism is disengaged from the
motor drive plate.
b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm.
c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either
direction.
(1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot
shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and
Installation. (Figure 4)
(2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal
Workshop Manual diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page
11464
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071013A 2003-2007 0.7 Hr.
Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To
Verify Concern (Do Not Use With 40860B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17C426 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative
Wiper Pivot: All Technical Service Bulletins Wipers/Washers - Rear Wiper is Inoperative
TSB 07-10-13
05/28/07
REAR WIPER INOPERATIVE
FORD: 2003-2007 Expedition
LINCOLN: 2003-2007 Navigator
This article supersedes TSB 06-22-10 to update the vehicle model years.
ISSUE Some 2003-2007 Expedition and Navigator vehicles, the rear wiper may not return to park
position. In this case, the rear wiper system will attempt to park periodically causing a battery
drain.This concern may be caused by corrosion on the wiper pivot shaft assembly.
ACTION Use the following Service Procedure to identify and replace the rear window striker/wiper
pivot shaft assembly.
SERVICE PROCEDURE
1. Disengage rear wiper mechanism by partially opening the rear liftgate glass. (Figure 1)
2. Access the rear wiper arm attaching nut. (Figure 2)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative > Page 11470
3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm
throughout the entire travel of the wiper arm. (Figure 3)
a. This must be done while the glass is open so that the wiper mechanism is disengaged from the
motor drive plate.
b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm.
c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either
direction.
(1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot
shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and
Installation. (Figure 4)
(2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal
Workshop Manual diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is
Inoperative > Page 11471
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071013A 2003-2007 0.7 Hr.
Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To
Verify Concern (Do Not Use With 40860B)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17C426 42
Disclaimer
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > Page 11472
Wiper Pivot: Service and Repair
REAR WINDOW STRIKER AND WIPER PIVOT SHAFT ASSEMBLY
Removal
1. Remove the rear wiper pivot arm.
2. Remove the dust boot cover.
3. Remove the nut and the rear window glass handle.
4. Remove the nuts and the rear window striker and wiper pivot shaft assembly.
Installation
1. Remove the liftgate trim panel.
2. NOTE: An audible click should be heard as the striker engages the latch.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > Page 11473
Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft
pin should be aligned with the hole in the motor disc.
3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is
provided with the motor assembly.
1 Make sure the alignment tool fits over the motor disc and striker assembly.
2 Make sure the alignment tool clips are securely engaged.
4. Carefully close the liftgate glass.
5. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly
nuts.
6. Remove the rear window wiper motor alignment tool.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service
Bulletins > Page 11474
7. Close the liftgate.
8. Install the rear window wiper pivot shaft nut and handle.
9. Install the dust boot cover.
10. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn
the rear window wiper switch to OFF.
11. Install the rear wiper pivot arm onto the rear window wiper motor shaft.
1 Position the wiper pivot arm onto the rear window wiper motor shaft.
2 Tighten the nut.
3 Install the cover.
12. Open the liftgate. 13. Install the liftgate trim panel. 14. Test the liftgate and liftgate glass for
normal operation.
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
View 151-14 (Steering Column)
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
11478
Wiper Switch: Diagrams
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
11479
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
11480
Wiper Switch: Testing and Inspection
Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN 5 (2005))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
11481
